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transcript
WELCOMES
YOU
RECEIVING STATE ENERGY CONSERVATION AWARD ON BEHALF OF SMC
POWER GENERATION LTD. FROM PRINCIPAL CHIEF ENGINEER CUM CHIEF
ELECTRICAL INSPECTOR(SDA),GOVT. ODISHA
ODISHA STATE
ENERGY CONSERVATION AWARD
STATE ENERGY CONSERVATION AWARD OWNED BY SMC POWER
GENERATION LTD., ON NATIONAL ENERGY CONSERVATION DAY
2015
AWARD
Brief Introduction
SMC group was established by Late Shri Sewa Ramji, a well
respected entrepreneur from Saharanpur, Uttar Pradesh, India
in the year 1982 when he started a Paper Mill. The group
entered in steel sector in the year 1988.
In the year 2003 SMC Power Generation Limited was started an
integrated steel plant in village Hirma in the district of
Jharsuguda, Odisha with capacities of Sponge Iron 200000
MTPA, Billet 250000 MTPA, Rolling Mill 180000MTPA & Power
33MW. The Company is well-known for its quality steel product in
the brand name 'SMC THERMEX 500 QST.
Plant Profile
The unit wise installed capacity with the year of commissioning is
furnished below.
Particulars Unit Capacity Year of Commissioning
Captive Power Plant MW 8 2004
MW 25 2007
DRI-Kiln-1 TPA 100000 2004
DRI-Kiln-2 TPA 100000 2007
Steel Melting Shop TPA 250000 2007
Rolling Mill TPA 100000 2007
Rolling Mill TPA 80000 2013
PLANT PROCESS FLOW DIAGRAM
AFBC
WHRB-2
SMS ROLLING
MILL BILLETS
TG25
TG 8
IRON ORE
CRUSHER
COAL
CRUSHING
UNIT
KILN SPONGE IRON
WHRB-1
GRID
SMCPGL is comprised of Captive Power Plant. The requirement
of electricity for processes is primarily met from CPP (1x25 MW)
& (1x8 MW) with both coal based and Waste Heat Recovery type
generation.
The MRSS of SMCPGL is connected to the Kuchinda state grid
for import/export based on exchange of power.
The major energy sources of the plant are coal, LDO, HSD, HFO
and Electricity.
ENERGY & UTILITY SCENARIO OF THE PLANT
STATEMENT OF SPECIFIC ENERGY CONSUMPTION PUBLISHED
BY MINISTRY OF POWER, GOVT. OF INDIA.
Name, Address
and State
Specific energy
consumption
(TOE/T of
product) in base
line year
Product
Output
(Ton)
Specific energy
consumption
(TOE/T of
product) in target
year
SMC Power
Generation Ltd.
Hirma, Jharsuguda
Odisha
0.539 105094
0.512
PRODUCTION STATUS DURING THE YEAR 2012-13
PRODUCTION STATUS DURING THE YEAR 2013-14
PRODUCTION
0.00
20000.00
40000.00
60000.00
80000.00
100000.00
120000.00
140000.00
160000.00
180000.00
200000.00
base line year FY 2012-13
Total EnergyConsumption of PlantAnnual TOE
Total EquivalentProductSI+SMS+OthersAnnual Tonne
COMPARISION OF TOTAL ENERGY CONSUMPTION VS.PRODUCTION
IN BASE LINE YEAR 2012-13
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
base line year FY 2012-13
specific energy consumption
base line year
FY 2012-13
COMPARISION OF SPECIFIC ENERGY CONSUMPTION
IN BASE LINE YEAR 2012-13
0.00
20000.00
40000.00
60000.00
80000.00
100000.00
120000.00
140000.00
160000.00
180000.00
200000.00
FY 2012-13 FY 2013-14
Total EnergyConsumption of PlantAnnual TOE
Total EquivalentProductSI+SMS+Others AnnualTonne
COMPARISION OF TOTAL ENERGY CONSUMPTION IN
THE YEAR 2012-13 & 2013-14
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
FY 2012-13 FY 2013-14
specific energy consumption
FY 2012-13
FY 2013-14
COMPARISION OF SEC FOR THE YEAR 2012-13 & 2013-14
0.00
20000.00
40000.00
60000.00
80000.00
100000.00
120000.00
140000.00
160000.00
180000.00
200000.00
FY 2013-14 FY 2014-15
Total EnergyConsumption of PlantAnnual TOE
Total Equivalent ProductSI+SMS+Others AnnualTonne
COMPARISION OF TOTAL ENERGY CONSUMPTION IN
THE YEAR 2013-14 & 2014-15
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
FY 2013-14 FY 2014-15
specific energy consumption
FY 2013-14
FY 2014-15
COMPARISION OF SEC FOR THE YEAR 2013-14 & 2014-15
To reduce the specific energy consumption after the base line year we had
taken several encon projects like installation of VFD’s in our major energy
consuming equipment's such as
a) Installed VVFD in PA fan of AFBC boiler.
b) Installed VVFD in CWP motor of our 8MW TG set.
c) Installed hot billet conveyor belt system from SMS to Rolling Mill to carry
out the hot billet directly from SMS to rolling Mill for TMT production. This
could save a huge amount of thermal energy as the reheating of billets
could be avoided.
The detailed project cost and saving achieved are as under.
d) In place FO we use biomass firewood for laddle heating.
The major saving we record from the hot billet conveyor system as shown below
STEPS TOWARDS ENERGY SAVINGS
STEPS TOWARDS ENERGY SAVINGS
ROLLING MILL
Online Hot Billet Charging through High Speed Conveyor
• Hot Billet Shearing machine taken in PLC Automation
• Online Temperature Monitoring Pyrometer
STEPS TOWARDS ENERGY SAVINGS
ROLLING MILL
• Installed HMI PLC automation for Hot
billet shifter to reduce reject of Billets
STEPS TOWARDS ENERGY SAVINGS
ROLLING MILL
• Installed Hot Billet
counter
• Installed Water flow
meter for accurate
water measurement
in Rolling Mill
STEPS TOWARDS ENERGY SAVINGS
STEEL MELTING SHOP
TDU IMPLEMENTED
• Installed True Demand Utilizer
for Load Sharing & controlled
• Export / Import
STEPS TOWARDS ENERGY SAVINGS
SPONGE IRON DIVISION
Implemented AC Drives for CB / ABC / Shell-air fans & Lobe Compressors
• Maximum Power Consumption Save & Productivity increases
• Maintain Operation measures
• Fuel Oil consumption reduces from 5800 litres to 4500 litres (Light-up)
• Specific Coal consumption reduces fro 0.50 % up to 0.46 % C/Fe
• Coal Consumption reduces from 1.7 ton to 1.2 ton
• Steam generation increases up-to 25 ton/Hr to 28 ton/Hr
• Unit Per Ton achievement from 77-80 tons to 58-65 tons(High Production)
Sl.
No.
Details of energy
efficiency
improvement
measure
Investment
in Rs.
Verified
Savings in
Rs
Verified
savings
Energy
Units Fuel Remarks Completion
Date
1 VFD INSTALLED
IN PA FAN AFBC 3,00,000 6,26,340 120 MWh/Yr.
10.36
TOE/Yr.
2
HOT BILLET
CONVEYOR BELT
SYSTEM
ADOPTED FOR
ROLLING MILL.
61,24,350 109141898.5 9123.334 MWh/Yr 5.33
TOE/Yr.
REHEATING
OF BILLETS
NOT
REQUIRED
FOR
ROLLING
MILL
FY 2013-14
3
COOLING WATER
PUMP MOTOR-
1(250KW)
4,00,000 14,23,500 274 MWh/Yr. 23.54
TOE/Yr.
Some of our energy saving measures that we have
taken in the recent past to reduce SEC
Sl. No. Details of energy efficiency
improvement measure
Investment -
(Rs. Estimated)
Verified Savings
(Rs. Estimated)
Verified savings -
Energy Savings
Estimated
Units Fuel
1 COMPRESSOR-1(SID) 2,00,000 4,27,050 82 MWh/Yr. 7.06MTOE/Yr.
2 COMPRESSOR-1(SID) 2,00,000 4,27,050 82 MWh/Yr. 7.06MTOE/Yr.
3 COMPRESSOR-1(SID) 2,00,000 4,27,050 82 MWh/Yr. 7.06MTOE/Yr.
4 COMPRESSOR-1(SID) 2,00,000 4,27,050 82 MWh/Yr. 7.06MTOE/Yr.
5 COMPRESSOR-1(SID) 2,00,000 4,27,050 82 MWh/Yr. 7.06MTOE/Yr.
6 COMPRESSOR-1(SID) 2,00,000 4,27,050 82 MWh/Yr. 7.06MTOE/Yr.
7 COMPRESSOR-1(SID) 3,50,000 9,11,040 175 MWh/Yr. 15.07MTOE/Yr.
8 COMPRESSOR-1(SID) 3,50,000 9,11,040 175 MWh/Yr. 15.07MTOE/Yr.
9 COOLING WATER PUMP 2 (250KW)
LT MOTOR 4,00,000 14,23,500 274 MWh/Yr. 23.54MTOE/Yr.
10 COOLING WATER PUMP 3(250KW)
LT MOTOR 4,00,000 14,23,500 274 MWh/Yr. 23.54MTOE/Yr.
11 BOILER FEED PUMP-1(180KW) LT
MOTOR 3,70,000 10,24,920 197 MWh/Yr. 16.95MTOE/Yr.
12 BOILER FEED PUMP-2(180KW) LT
MOTOR 3,70,000 10,24,920 197 MWh/Yr. 16.95MTOE/Yr.
13 BOILER FEED PUMP-3(180KW) LT
MOTOR 3,70,000 10,24,920 197 MWh/Yr. 16.95MTOE/Yr.
14 CONDESATE EXTRACTION PUMP-
1(55KW) LT MOTOR 1,75,000 3,13,170 60 MWh/Yr. 5.18MTOE/Yr.
15 CONDESATE EXTRACTION PUMP-
1(55KW) LT MOTOR 1,75,000 3,13,170 60 MWh/Yr. 5.18MTOE/Yr.
ENERGY CONSERVATION PROJECTS UNDER IMPLEMENTATION
Sl. No. Details of energy efficiency improvement measure
1 LOBE COMPRESSOR-1(110KW) LT MOTOR
2 LOBE COMPRESSOR-1(75KW) LT MOTOR
3 PSB ID FAN(110KW) LT MOTOR
4 CB FAN-1(45KW) LT MOTOR
5 CB FAN-2(45KW) LT MOTOR
6 COOLER MAIN DRIVE-1(150KW) LT MOTOR
7 COOLER MAIN DRIVE-2(150KW) LT MOTOR
8 LOBE COMPRESSOR-2(75KW) LT MOTOR
9 TRANSPARENT ROOF SHEET TO BE INSTALLED IN DG ROOM, TG BUILDING, COMPRESSOR
HOUSE FOR EFFICIENT USE OF DAY LIGHT
10 ASTRONOMICAL TIMER SWITCH TO BE INSTALLED FOR STREET LIGHTING SYSTEM.
11 LED LIGHTS ARE TO BE USED FOR OFFICE LIGHTING.
12 CAPACITOR BANK 500KVAR AUX.PANEL-1
13 CAPACITOR BANK 500KVAR AUX.PANEL-2
Our dedicated team of energy cell is continuously doing efforts for save every single unit of
energy & we have some more Energy saving projects to be implemented in the upcoming year.
ENERGY SAVING MEASURES TO BE IMPLEMENTED
We have constructed 4 no. of reservoir for rain water harvesting.
Reservoir-3
Reservoir-1 Reservoir-2
Reservoir-4
The water generated from the domestic source is collected in the Sewage pond /
Settling pond by connecting all the drainage system of the plant to the settling
pond. Since the settling pond is some water at lower level than plant site the
waste water getting collected easily without pumping. which we are using for road
sprinkling and in other purposes like conditioning of ash etc. later on.
SAVE ENERGY
SAVE NATION
SAVE WORLD