1 Hospet Steels Limited DRIVING INNOVATION Infinite resolve September 1 st & 2 nd – 2010 Chennai. 11 th National Award for “Excellence in Energy Management – 2010” Team Leader : Mr.Ananda Bhattacharjee - DGM Energy Managers : Mr.Naresh - Manager : Mr.Y.D.Guruprasad – Dy.Mgr Green field project conceived in 1995. Strategic Alliance between “Mukand” & “Kalyani” groups to produce world class Alloy steel. Both the groups are Leaders in Alloy & Special Steels. Capacity : 7,00,000 MT /Annum. HSL product ranges are - Bloom - Billet - Rolled products Energy Cost as % of Manufacturing cost is 53. ISO TS 16949, ISO 14001, OHSAS 18001 & TPM certified company. COMPANY PROFILE Infinite resolve DRIVING INNOVATION
Road map to achieve Benchmark 5.25 G Cal/MTProcess Initiative:
1.4
92
7.28
653
As on08-09
0.0131.351.5Ltr/TOptimization of LDO consumption in caster
0.00178890Kwh/MT
Optimization of LRF power consumption
0.052
0.09
Reduction in Gcal/T
5.6
610
Target 10 - 11
6.00
622
As on 09-10
Lit/TReduction in FO Consumption by introduction of copper coil in boiler feed water heating through Gasifier system.
Kg/TOptimization of Coke Rate by enhancing MBP blowers efficiency of MBF 2
UOMActions
Road map to achieve Benchmark 5.25 G Cal/MTProject Initiative:
0.024
0.027
Benefit in SEC
0.000020
0.0001
Reduction in G Cal/T
Saving in PowerDay lighting system in Admin building
Saving in PowerReplacement of Electric Geyser with Biomass water heating system
BenefitActions
Total expected saving in G Cal – 0.154
9
Innovation Leads to Excellence
DRIVING INNOVATION Infinite resolve
Hospet Steels Limited
v Investment = Rs. 5 Lakhs v Savings in FO = 0.3 ltr/MTv Saving/Annum = Rs. 45 lakh/annum.v Payback period = 45 days
1.BIOMASS GASSIFIER SYSTEM
100 kg/hr Biomass gassifier
Water heating coil inserted in the chamber
• First time introduced steel industry for heating boiler feed water
• In house development
• Copper coil is being introduced in Aug’10 to improve water temperature
10
2. DAY LIGHTING SYSTEM A NEW CONCEPT
v Investment = Rs. 4.7 Lakhs
v Savings in kwh = 9600 kwh/annumv Payback Period = 9 years
Light pipe collects the sun light from the roof and it transmitted to the room without any battery back up.
Before After
During rolling process the bloom size is gradually reduced to finish size by rolling in different passes & these passes have been reduced by increasing the draft from 30 mm to 45 mm.
No of passes before increase in draft = 11
No of passes after increase in draft = 9
Increase in productivity = 6 MT/hr
Savings in FO = 168 Kl p.a
Savings / annum = Rs.47 Lakhs
Payback Period = Immediate.
3. Reduction in Rolling time
11
4. Reduction Hot Saw blade Changing timeBefore: Hot saw blade cover was being removed and put back by EOT crane. Blade locking Nut was being tightened manually by using hammer.
After: Hinges provided to Blade cover to open & close, EOT crane avoided. Pneumatic torque wrench introduced for tightening blade locking nut.
Hot saw blade change time before modification = 30 mins
Hot saw blade change time after modification = 20 minsNo of blade change = 2 nos/dayPower saving due to reduction in Mill idle time = 91000 unit p.aSavings in FO due to reduction in Mill idle time = 8050 lts p.a
Savings / annum (Power & FO) = Rs.27 Lakhs
Payback Period = Immediate.
Hinges
5. Reduction in Power Consumption of Hyd systemBefore: Two motors of 36 KW each were running in reheating pusher hyd. System
After: Two motors replaced with single motor of 45 KW. Modification done on hydraulic system. Dual pumps (one pump having high flow and low pressure, another pump having low flow and high pressure) connected to single motor.
Power consumption with two motors of 36 KW each = 302400 units p.a
Two motors replaced with Single motor of 45 KW = 189000 units p.a
Savings / annum = Rs.5.67 Lakhs
Payback period = 13 months
12
Environmental Projects
No of Tree Plantation to protect GHG
26550 27150 2832032575
2400016400
1000
11000
21000
31000
41000
2005-06 2006-07 2007-08 2008-09 2009-10 2010-11
Nos o
f tree
s
% of plantation area
10%20%
33%40% 45% 48%
0%
20%
40%
60%
2005-06 2006-07 2007-08 2008-09 2009-2010 2010-11
Year
%
Approx total power plant project cost503
Depends up on CER rate in the market
Estimated4204766969
Verification audit completed & under going registration.1st year2nd year
BF gas firing system in Boiler #2 of Power plant #2 (U/P)
2
Approx total power plant project investment 280
Depends up on CER rate in the market
69589681355040036854
2006200720082009
BF gas firing system in Boiler #1 of Power plant #1
• Zero water discharge out side the plant premises ensured through 100% effluent treatment and recycling.
• Check dam of capacity increased from 50,000 m3 to 75000 m3 for Rain water harvesting. – 2009-10
• 3 Guard pond are constructed to 100% reuse of wastewater from the plant for various purposes.
• The wastewater generated in cooling of EOF, MBF’s is treated in Thickener & recycled.
• Secondary De-dusting system for controlling Fugitive Emissions at LRF & EOF..
• Canteen waste & House-hold garbage are utilized in bio-gas plant.• STP water is used for plantation through drip irrigation.• ETP treated water used for gardening.• STP cum ETP of capacity 50m3 / day is being installed at Contract
workers canteen. 2010-11• Reusing of MBF granulated slag making pavement bricks.• Environment lab established for continuous monitoring of stacks
and ambient air quality. 2009-10. • ETP & STP water quality lab established. 2009-10.
Major environmental improvements
Plant Specific Water Consumption
2.27
5.00
2.43 2.493.823.63
5.00
0.001.002.003.004.005.006.00
05-06' 06-07' 07-08' 08-09' 09-10'Year
M3/M
T of S
teel
M3/MT National Benchmark M3/MT by CPCB
14
Encon Program Management Methodology
Encouragement for participation
Suggestions referred to EC Cell
Evaluation of the projects
Co-ordination for Management Approval
Implementation TPM /SIX SIGMA Tools
Review by Chief Executive
Not effective
Identification of Encon & Involvement of employees.
Completed in Sep 08
2.technician, 4.labors& 1.Manager
2008-09Utilization of waste heat from tundish to preheat Sub Entry Nozzle. (LPG saving)
3.
Completed in Feb 10
1technician 2.labors& 1.Electrical engineer.
2009-10Installation light pipe (daylight) in PPC & SMS meeting hall
2
Completed in Aug 09
2 Technicians 3.contract labors 2.Engineer.
2009-10Biomass grassfire system for heating boiler feed water
1
Progress of implementat
ion
Extent of man-power involved
***
Idea originated
in FY **
Source of ECON idea *SN
15
AUDIT FINDINGS:
ISO 14001:2004Product Name :
1034314Re-CertificationJob Description/Code:
170.37KALYANI STEELS LTDCompany Name/Code
S.G. SahuContact(s) :
Team Member(s) :Operations - KalyaniSteels
Department :
G KarthikeyanTeam Leader :4.4.6 Operational controlClause :
GKA/01Number :17/03/2010Date(s) :
MinorType of findings :
Standard requirement : The organization shall identify and plan those operations that are associated with the identified significant environmental aspects consistentwith its environmental policy, objectives and targets, in order to ensure that they are carried out under specified conditions, by stipulating the operating criteria in the procedure(s).Non conformity : The operation control procedure OCP/work instruction EMS/WI/KSL/4.4/05 for the operation of furnace does not specify the operating criteria forthe air fuel oil ratio and the operation of recuperator to minimise the air pollution, which is required as per the environment Management system manual.
Non Conformity
Corrective Action Report (to be completed by the company) :
Mr.S.B.BurdeCompany Representative :
25.03.10Proposed Completion Date
CORRECTION: Exact Fuel Oil ratio is mentioned.ROOT CAUSE: Exact Fuel Oil ration was not mentioned (Lack of Documentation).CORRECTIVE ACTION: The documentation of the Work Instructions was carried out as per the requirements of Environmental Management System.
Final Clearance22.03.10Actual Completion date
18/08/10
AUDIT FINDINGS :
ISO 14001:2004Product Name :
1034086Re-CertificationJob Description/Code:
172.37MUKAND LIMITEDCompany Name/Code
Final Clearance22.03.10Actual Completion date
Correction: Aspects related with concerns of interested Parties are identified and documented in “List of Aspects and Impacts”.Root Cause: Lack of awareness.Corrective Action: Concerns of interested parties while documenting the “ List of Aspects and Impacts”Was carried out as per the requirements of EMS.
Corrective Action
Mr.S.B.BurdeCompany Representative :
25.03.10Proposed Completion Date
Corrective Action Report (to be completed by the company) :
Standard Requirement: The organization shall establish, implement and maintain a procedure(s)a) to identify the environmental aspects of its activities, products and services within the defined scope of the environmental management system that it can controland those that it can influence taking into account planned or new developments, or new or modified activities, products and services, andb) to determine those aspects that have or can have significant impact(s) on the environment (i.e. significant environmental aspects).The organization shall document this information and keep it up to date.The organization shall ensure that the significant environmental aspects are taken into account in establishing, implementing and maintaining its environmental management system.Observed Non-Conformity: There is no evidence of considering the aspects related concerns of interested parties in the identification of significant environmental aspects as required by the procedure No. HSL/EOHSMS/P/4.3.1/02, Revision 01, dated 15.03.2009.
Non Conformity
MinorType of findings :
B S SridharContact(s) :
Team Member(s) :UtilitiesDepartment :
Vineet M SarwadeTeam Leader :4.3.1 Environmental aspects
Clause :
VS0/01Number :20/03/2010Date(s) :
18/08/10
16
Energy Conservation Project Reporting Format
PaybackDetailInvestment
One TimeaRecurring
Savings per year:
Implemented on:Team members:Care taker:
Project details:
Background
OPRUTLMechElecEnergy Saving at:Theme:
Completion Date
Start DateProject No.
Daily Prodn and Energy consumption ReportProdn Date:
Particulars UOM Target For the Day Till Date
MBF1 Production MT 550MBF2 Production MT 550MBF3 Production MT 800Total MT
Partly reused in the process, Sold to outside parties, partly used in the construction of internal Roads
9140083,4291,06,121TPASMS Slag8
Sold to outside parties1680615,88721,374TPAEOF Sludge7
Sold to the KSPCB Authorised Party.
--13,998LPAWaste Oil (Haz. Waste)
6
Reused in the EOF296810113TPAPig Iron Scrap
5
Reused in the EOF & used in the Construction of Roads
2616523,08024,810TPAMBF Slag4
Sold to the outside parties & Partly reused in the construction of internal roads.
1402871,14,91586,165TPAG Slag3
Sold to the outside parties1483051,36,4261,53,023TPAIron Ore Fines
2
Sold to the outside parties & used in EOF & LRF
4198937,03626,847TPACoke Fines1
2009-102008-092007-08
DisposalQuantityUnitType of Waste
SN
18
v HSL has taken drive to reduce 3-5% of conventional energy in 3 - 5 years.
v Actions initiated so far are:
ü Use of Bio mass for process heating & canteen
ü Bio gas in canteen
ü Jatropha plantation in the plant area about 25 acres. Seeds are planted to produce bio diesel to use in company vehicles.
ü Light pipe (Day lighting system).
ü Solar water heating system.
Renewable Energy Drive
Turbo ventilators Translucent Sheets
Involving Associates in ENCON
• M/s.Kalyani Steels Ltd, Pune and M/s.Mukand Ltd, Kalwe are our promoters and pioneers in Alloy Steel Making, with whom we carryout our regular interaction for Encon.
• CII is auditing our plant for Energy and water since three years. Almost all the suggestions of CII are complied.
• M/s Nalco is our associate for water conservation as a part of Total Water Quality Program
• M/s Appropriate Rural and Renewable Energy Institute, Pune an NGO, M/s Phoenix Products Belgaum and Sky shade Daylight, Hyderabad are our associates for implementation of renewable energy projects at our plant.
19
% Breakup of time currently spent (Average basis) by Senior Executives in various functions
v Strategic Planning - 20%
v Product Development - 5%
v Costing - 10%
v Training & Development - 10%
v Optimization of available resources - 10%
v Building Management Systems - 5%
v Improving Environmental effectiveness - 5%
v Corporate social responsibilities - 5 %
v Technology up gradation - 10%
v Safety Management - 10%
v Quality Management - 10%
Future Plans
v Coke Oven plant for better quality coke and to further reduction in coke rate.
v Sinter Plant to recycle the process wastes and improve BF productivity.
v New15 MW power plant by utilizing excess BF gas available
20
HOSPET STEELS LTD
National Award for Excellence in Energy Management Received from CII
HOSPET STEELS LTD
National Award for Excellence in Water Management Received from CII
