19th national award for excellence in energy management 2018€¦ · siltara industrial growth...

© Confederation of Indian Industry

VANDANA GLOBAL LIMITED

(Leading the New )

Siltara Industrial Growth Center,

Phase – II, Siltara, Dist. - Raipur

(Chhattisgarh)

Mr. M. Subba Rao, AVP

Mr. Nilesh Jadhav, Energy Manager

19th National Award For Excellence in Energy Management 2018


Brief Introduction – Corporate Profile

▪ Established in 1996.

▪ Among the largest Manufacturers of Steel -

TMT Bar, Wire Rod, Sponge Iron, Silico

Manganese, Ferro Manganese manufacturing &

Generation of Power in India

▪ Over 1,000 professionals.

▪ Vandana Global today boasts of successes in a

range of domains including manufacturing of

sponge Iron, TMT bars, Wire rods, Ferro Alloys,

Mining, Power (Thermal, Solar, and Wind)


Brief Introduction – Plant Profile & Specification

Sl No. Division Plant Capacity Production Capacity

1. Power Plant WHRB 14 MW, AFBC 24 MW &

Solar (550 kWp)

38 MW

2. Ferro Alloys (SAF) 2 Nos. x 9MVA & 1 Nos. 18MVA 36000 MTPA

3. Sponge Iron 1 Nos. x 200 TPD

1 Nos. x 500 TPD

231000 MTPA

4. Steel Melting Section 540 TPD (Induction Furnace) 178200 MTPA

5 Rolling Mill (Hot Charging) 540 TPD 178200 MTPA

No. of Employees : 1375

Plant Area (Industrial Area) : 56.91 acres

Plant Commencement Year : 2001

Last Year’ Annual Turn Over : Rs. 747.86 Cr (FY 17-18)

Last year’s Investment in : Rs. 381.13 Cr (FY 17-18)

Plant Capacity / Year : 0.2 Million Tonne


Brief Introduction – Process Layout

Hot Billets

Rolling Mill

SAF

(2Nos. x 9MVA & 1Nos. 18MVA)

Sponge Iron

PlantSMS Plant

DRI Unit (200 TPD

& 500 TPD)

Coal, Iron Ore,

Flux, etc.

Sponge Iron &

Dolochar

WHRB

(30 TPH)

WHRB

(55 TPH)

AFBC (90 TPH)

AFBC (90 TPH)

Power Station(TG - 8 MW , 30 MW,

Solar 550 kWp & Import

Power)

Dolochar, Coal

Sponge, Power,

Scrap, etc.

Steel Melting

Section (IF)

CCM (Billets)

Rolling Mill

TMT and Wire

Rod Mill

Raw Materials (Mn Ore, Coke,

Quartz, Dolomite)

Silico Manganese

Sponge Iron Sell

Dolochar

Electricity

Billets Sell

Sponge Iron

Electricity

Power

Plant

Ferro Alloy

Plant


Brief Introduction – Finished Product

OUR FINISH

PRODUCT

Silico Manganese

MS Billet

TMT Bars Wire Rod

Sponge Iron

Power


▪ FY 16-17, our SEC was increased due to major breakdown at Plant & It reflects in our SEC & utilization factor

along with non availability of raw materials like coal, iron ore etc.

▪ Our Major Reduction in SEC due to

1. Introduction of coal additives at boilers.

2. Optimization of coal consumption in Sponge Iron Kilns by changing the feed to Injection Ratio

1. Sp. Energy Consumption in last 4 years


▪ PAT Cycle 1

▪ We were given the target for PAT cycle 1 as 0.7826 MTOE/ton.

▪ We have achieved target & received ESCerts of 19502 Nos in PAT Cycle 1

▪ PAT Cycle 2

▪ For PAT Cycle 2, we got target of 0.7216 MTOE / ton with production of 230076 Ton.

Comparison on Specific Energy Consumption with Similar Plant

2. Information on Competitors Benchmark – PAT Cycle 2 Target

Sr.

No.

Particulars VGL 1st

Competitor

2nd

Competitor

3rd

Competitor

National

Benchmark

Global Benchmark

for Crude Steel

1 Specific

Energy

Consumption

(Gcal / ton)

6.0 6.28 5.45 6.42 5-5.5 4.5–5.5


▪ With the increasing demand & cost of energy / water, we are undertaking energy & water audits to be more

efficient and to curtail costs. We are geared up with internal Audit team & external auditors to achieve these

targets.

▪ We have developed well equipped internal audit team with following set of instruments.

▪ Three Phase Power Analyzer

▪ Ultrasonic Flow Meter

▪ Thermal Imager

▪ Compressed Air Flow Meter

▪ Psycho Meter (swing type)

▪ Ultrasonic Leak Detector

▪ Digital Photo Tachometer

▪ Infrared Thermo Meter

▪ Anemometers

▪ Lux Meter

▪ Pressure Meter / Gauges

▪ Pitot Tube

▪ Our internal audit team conducts audits of total plant on consistent basis & support to achieve desired

target.

▪ Also support for equipment selection, implementation & quantification of actual savings after implementation.

2. Road Map to Achieve Target (Contd.)


▪ For achieving the targets, following energy conservation projects have been undertaken during the year 2018-19.

▪ We have engaged CII for energy Audit of entire plant for further reduction of SEC of plant, which is under

progress.


Sr.

No.

Recommendations Energy Unit Estimated

Saving (Rs.

Lakh)

Investment

(Rs. Lakh)

1 SEC of service air compressors of sponge iron & Ferro Alloys are been taken

for major maintenance

kWh 11 10

2 Ferro 9 MVA ID Fan motor - Replace Existing Motor (250 kW) with low

Capacity motor (132 kW) Since Actual loading on motor is minor (30-38%)

kWh 11 7

3 Capacity Enhancement of AFBC 1 ID Fans (Two Nos.) to avoid operation of

two fans

kWh 34 40

4 Implementation of Temp Shield Kiln Coat - Nano-porous ultra-thermal

insulation on 500 TPD Kiln

kWh 3.25 1.18

5 WHRB ID fan 3 – Replacement of Fluid coupling with Drive along with Fan

replacement

kWh 35 45

6 FAD Testing & Arresting Compressed air leakages kWh 20 Minor

Total 114.25 103.18


▪ We follow below Strategy for Achieving Target

▪ To undertake energy audit so as to identify areas for energy saving, both without and with investment

▪ To draw out the implementation action plan for reducing energy cost for the plant on a sustained basis

▪ Expedite action plans for reduction in energy, water and fuel costs

▪ Implementing renewable energy solutions, waste heat recovery projects

▪ Identifying & implementing opportunities in reducing the carbon footprint of our organization

▪ Providing training to end users for better understanding of our assets and their current operational status

including maintenance requirements.

▪ We work with Team – Our specialists hand hold our team and provide support during the implementation

phase to realize the benefits of energy savings

▪ Knowledge transfer – We are committed to transferring knowledge to our team to realize benefits from

continuous energy audits and conservation measures



Sr.

No.

Recommendations Energy Unit Actual Saving

(Rs. Lakh)

Investment

(Rs. Lakh)

A. Without / Minor Investment

1 Reduce operating hour of Clarified pump by opening full valve and trimming

existing impeller

kWh 2.5 Nil

2 Reduce the damper loss in Kiln-1 by reducing the speed of the motor by

existing VFD and open the in Shell air fans

kWh 1.3 Nil

3 Reduce the damper loss in Kiln-2 by reducing the speed of the motor by

existing VFD and open the damper to maximum possible extent in Shell air

fans

kWh 0.5 Nil

4 Stop recirculation from cold well to hot well and reduce operating hours of

one hot well pump

kWh 1.1 Nil

5 Modify the present de-dusting system of kiln-2 kWh 1.7 Minor

Total (Without / Minor Investment) 7.1 Nil

B. With Investment & Payback Less Than 2 Years

1 Installation of VFD at Multi grade Filter Pump kWh 4.5 1

2 Installation of VFD at CWP 2 (TG 2) kWh 6.0 2.5

3 Installation of VFD at CWP-3 (TG-1) kWh 1.0 1.8

4 Installation of VFD at ACW Pump-1 kWh 2.6 1

5 Installation of VFD at Bag Filters Fans (Primary Crusher ID Fan) kWh 3.8 1

6 Installation of VFD at (Secondary Crusher Id Fan) kWh 0.7 1

7 Installation of VFD at Transfer House Id Fan kWh 0.50 1

8 Installation of VFD at Boiler Bunker Id Fan kWh 2.0 1

9 Installation of VFD in CEP-1 (33MW) kWh 3.0 1.5

3a. Energy Saving projects implemented in FY 2015-16


Sr.

No.


(Rs. Lakh)

Investment

(Rs. Lakh)

B. With Investment & Payback Less Than 2 Years (Contd.)

10 Installation of VFD in CEP-2 (33MW) kWh 3.0 1.5

11 Installation of VFD in at BFP-1 (WHRB-2) kWh 12.5 2.1



14 Installation of VFD in at CEP (8MW) kWh 3.1 1.2

15 Installation of Auto Drain valve at compressor network kWh 1.0 0.5

16 Cooling Tower 1 -(8 MW) Fan Replacement with FRP Blade kWh 2.3 1.2





21 Lighting Energy Saver-40 kVA WHRB kWh 0.6 0.5

22 Lighting Energy Saver-27 kVA Switch Yard Coal yard kWh 0.5 0.5

23 Lighting Energy Saver-40 kVA Switch Gere FBC kWh 0.4 0.5

24 Lighting Energy Saver-40 kVA TG Building kWh 0.6 0.5

25 Replacement of Soot Blowers with Sonic Horn kWh 25.8 18

26 Install VFD at Cold Well Pump-2 of Kiln-1 kWh 2.0 1.2

27 Install VFD in Kiln-2 for CB fan motor to avoid damper loss. kWh 1.8 1.2

28 Install VFD in Kiln-1 de-dusting fan -4 motor to avoid damper loss kWh 2.1 1.5

29 Install VFD in CB fan motor for Kiln -1 to avoid damper loss kWh 0.5 1

3a. Energy Saving projects implemented in FY 2015-16 (Contd.)



Sr.

No.


(Rs. Lakh)

Investment

(Rs. Lakh)

B. With Investment & Payback Less Than 2 Years (Contd.)

30 Install VFD in PSB bag filters fan at SID to avoid damper loss kWh 1.3 1.2

31 Install VFD in Cold Well Pump-2 for Kiln-2 kWh 1.0 1.2

32 Cooling Tower Fan 1- 500 TPD Fan Replacement with FRP Blade kWh 0.6 1


34 SID Lighting Energy Saver 18 KVA kWh 0.40 0.5

35 SID Lighting Energy Saver 18 kVA kWh 0.4 0.5

36 Star-del Starter at SID RMP 10 Nos. Belt Conveyors kWh 3.2 3.5

37 Install VFD in RWP-1 at Continuous Cast Machine (CCM 1) kWh 3.1 1.1

38 Install VFD in RWP-1 at Continuous Cast Machine (CCM 2) kWh 3.6 1.1

39 Install VFD in Soft Water Pump at Induction Furnace -2 kWh 1.3 1

40 Install VFD in Soft Water Pump at Induction Furnace -1 kWh 0.6 1

41 SMS Lighting Energy Saver 9 kVA kWh 0.4 0.35

42 SMS Lighting Energy Saver 18 kVA kWh 0.4 0.35

43 FRP fan at 5 SMS Cooling Towers kWh 2.5 4.5

44 VFD at ID Fan Furnace 1-250 KW kWh 7.0 4

45 VFD at ID Fan Furnace 2-250 KW kWh 7.0 4

46 VFD at Sinter Plant old ID Fan 55 KW kWh 2.1 1.8



49 VFD at Sinter Plant old ID Fan 37 KW kWh 1.7 1

Total ( Investment & Payback Less Than 2 Years) 151.3 96.9



Sr.

No.


(Rs. Lakh)

Investment

(Rs. Lakh)

C. With Investment & Payback Greater Than 2 Years





Total (With Investment & Payback Greater Than 2 Years) 2.1 4.4

Summery of Implemented Project FY 15-16

Sr.

No.

Recommendations No. of Recommendations

Implemented

Actual Saving

(Rs. Lakh)

Investment (Rs.

Lakh)

1 Without / Minor Investment 5 Nos. 7.1 Nil

2 With Investment & Payback Less Than 2

Years

57 Nos. 151.3 96.9

3 With Investment & Payback Greater

Than 2 Years

4 Nos. 2.1 4.4

Total 66 Nos. Rs. 160.5 Lakh Rs. 101 Lakh


3b. Energy Saving projects implemented in FY 2016-17

Sr.

No.


(Rs. Lakh)

Investment

(Rs. Lakh)


1 Air Pressure setting Changed from 6.5 - 7.5 kg/cm2 to 6-6.5 kg/cm2. kWh 0.96 Nil

2 WHRB - 1 - Optimization of ESP Heater operation. kWh 2.3 Minor

3 WHRB - 2 - Optimization of ESP Heater operation. kWh 3.9 Minor

4 FBC 1 - Optimization of ESP Heater Operation. kWh 3.9 Minor

5 FBC 2 - Optimization of ESP Heater Operation. kWh 3.9 Minor

6 TG 1 - MGF 1- 11 kW. Pump Efficiency improved by Maintenance kWh 1.5 Minor

7 TG 1 - MGF 2- 11 kW. Pump Efficiency improved by Maintenance kWh 1.9 Minor

8 TG 2 MGF 1- 30 kW. Pump Efficiency improved by Maintenance kWh 1.4 Minor

9 Furnace feeding pumps 9 MVA Pump 1. Efficiency is on lower side. Need to

do the Proper Pipe layout at Suction Side to improve performance of pumps

kWh 0.40 Minor


do the Proper Pipe layout at Suction Side to improve performance of pumps

kWh 0.46 Minor


do the Proper Pipe layout at Suction Side

kWh 0.38 Minor


do the Proper Pipe layout at Suction Side

kWh 0.41 Minor

13 Pump - Hot Water Pump 1. Recommended to improve by maintenance.

Cleaning of suction foot valve, strainer & NRV checking

kWh 1.9 Minor



kWh 1.2 Minor


3b. Energy Saving projects implemented in FY 2016-17 (Contd.)

Sr.

No.


(Rs. Lakh)

Investment

(Rs. Lakh)




kWh 1.3 Minor



kWh 0.9 Minor

Total (Without / Minor Investment) 26.6 Nil


1 Collect 100% dust from SID discharge & put in dust injection system. Install

separate bag filter so that power generation will improve.

Coal (MT) 74.2 62

2 SEC of SID compressors are on higher side. Need to take action kWh 9.5 6

3 SEC of both SMS compressors are on higher side i.e. 0.23 & 0.20 resp.,

Need to take action for reduction.

kWh 7.48 4

Total (With Investment & Payback Less Than 2 Years) 91 72


Sr.

No.


Implemented

Actual Saving

(Rs. Lakh)

Investment

(Rs. Lakh)


2 With Investment & Payback Less Than 2

Years

03 Nos. 91 72



3c. Energy Saving projects implemented in FY 2017-18

Sr.

No.


(Rs. Lakh)

Investment

(Rs. Lakh)


1 HE & CS Pump (15 kW x 2 Nos.-) - Shut down the operation of pump for the

Period of Rolling Mill Not in Running Condition.

kWh 1.3 No

2 Hot Water Pump (15 kW x 4 Nos.) - Shut down the operation of pump for the

Period of Rolling Mill Not in Running Condition.

kWh 1.6 No

3 Compressors - loading & unloading pressure reduced by 1-1.5 bar kWh 29.6 No

4 Arresting Compressed Air Leakages at various locations of compressors i.e.

at Conveying Line, compressor Header, Valves & boiler area

kWh 17.8 Minor

5 Arresting Compressed Air Leakages at various locations i.e. at TG Bldg.,

WHRB 1 & 2, AFBC 1 & 2, SILO area

kWh 19.6 Minor

6 Arresting Compressed Air Leakages at various locations i.e. at CCM 1, 2 &

other Furnace floor Areas

kWh 3.6 Minor

7 CTM Pump No. 4 – Efficiency Improvement by doing Maintenance kWh 1.0 Minor

8 CTM Pump No. 1 – Recommended to replace impeller kWh 0.2 Minor

9 CTM Pump No. 2 – Efficiency Improvement by doing Maintenance kWh 0.2 Minor

10 Raw Water Pump No. 2 – Efficiency Improvement by doing Maintenance kWh 0.3 Nil

11 CLF Pump No. 1 – Efficiency Improvement by doing Maintenance kWh 1.0 Minor




Total (Without / Minor Investment) 78.20


3c. Energy Saving projects implemented in FY 2017-18 (Contd.)

Sr. No. Recommendations Energy Unit Actual Saving

(Rs. Lakh)

Investment

(Rs. Lakh)


1 TG 1 - CWP Pump 3 - Efficiency on lower side 35%, needs to improve. kWh 12.3 1

2 Reduction of unburnt carbon in Fly and bottom ash in FBC-1 Coal (MT) 65.5 18.8

3 Reduction of unburnt carbon in Fly and bottom ash in FBC-2 Coal (MT) 77.6 22.3

4 CBC - 4 Installation of Star - Delta Converter kWh 0.8 0.6

5 Efficiency Improvement at CWP-1 pump at TG-1 (8 MW) kWh 8.3 1.0

6 Efficiency Improvement at of CWP-2 pump at TG-1 (8 MW) kWh 5.2 1.0

7 Raw water pump (55 kW) low efficiency, Replace with EE Pump kWh 0.3 11.0

8 Pump Replacement with EE pump at FC 04 RWPP 01 & 02 kWh 3.5 5.3

9 Pump Replacement with EE pump at FC 03 RWPP 01 kWh 4.5 5.9

10 Pump Replacement with EE pump at IF 1 RWPP 01 kWh 4.3 3.2

11 Pump Replacement with EE pump at IF 2 RWPP 03 kWh 4.2 3.4

12 Replaced Present TG 1 - MGF Pump No.2 with EE Pump or install VFD for

maintaining discharge pressure

kWh 0.5 2.8

13 Pump Replacement with EE pump at IF 2 SWPP 03 kWh 2.5 6.3

14 Installation of VFD on Low Pressure kWh 2.3 2.5

15 CBC - 5 Installation of Star - Delta Converter kWh 0.8 0.6

16 CBC - 1B Installation of Star - Delta Converter kWh 0.6 0.6

17 CBC - 1A Installation of Star - Delta Converter kWh 0.6 0.6

18 DMT Pump No. 1 - Recommended to install EE Pumps kWh 0.8 1.0

19 Installed VFD on TG 1 - CEP Pump No. 2 kWh 1.5 1.5

20 DMT Pump No. 2 -Recommended to install EE Pump kWh 0.8 1.0


3c. Energy Saving projects implemented in FY 2017-18 (Contd.)

Sr.

No.


(Rs. Lakh)

Investment

(Rs. Lakh)


21 Pump Replacement with Energy Efficient pump at CCM 1 Sec RWPP 01 kWh 6.7 0.6

22 Pump Replacement with Energy Efficient pump at CCM 1 Pri. RWPP 03 kWh 5.0 0.6

23 Installation of LED Lighting kWh 2.90 2.2

24 Replacement of Mill Pump kWh 2.9 1.0

25 200 TPD – CWP No. 1 – Recommended to replace with EE Pump. kWh 1.35 1.2

26 200 TPD – CWP No. 2 –Recommended to replace with EE Pump kWh 1.30 1.2

27 Installation of FRP CT Fans by replacing existing Fans at Ferro - 18 MVA kWh 2.40 3.0

28 DMT Pump No. 4 -Recommended to replace present pumps with EE Pumps kWh 0.5 1.0

29 500 TPD - CWP No. 1 – Recommended to replace Pumps with EE Pumps kWh 3.60 0.6

30 500 TPD - CWP No. 2 – Recommended to replace Pumps with EE Pumps kWh 3.70 0.6

31 Installed Star Delta Converter on Mixer Machine (37 kW) kWh 0.11 0.1

32 Optimization of Motor Capacity up to 22 kW instead of Hydraulic Machine

motor (90 kW) & Installation of Star-Delta Converter

kWh 0.22 0.1

33 Installation of insulation on bare valves, flanges, joints of main steam line kWh 1.8 0.2

Summery of Implemented Project FY 17-18 229.26 102.68

Sr.

No.


Implemented

Actual Saving

(Rs. Lakh)

Investment

(Rs. Lakh)


2 With Investment & Payback Less Than 2 Years 33 Nos. 229.26 102.68

Total 47 Nos. Rs. 307.46 Lakh Rs. 102.68 Lakh



Sr. No. Recommendations No. of Recommendations Implemented

Actual Saving (Rs. Lakh) Investment (Rs. Lakh)



3 With Investment & Payback Greater Than 2 Years 4 Nos. 2.1 4.4






2 With Investment & Payback Less Than 2 Years 03 Nos. 91 72







Total 47 Nos. Rs. 307.46 Lakh Rs. 102.68 Lakh

3d. Summery of Energy Saving projects implemented

161%91.6%


4. Innovative Projects Implemented

▪ Project 1: Achieving Coal Savings By “Reducing

Unburnt in Ash” – THERMACT

▪ THERMACT is a combustion catalyst.

▪ It converts the Inherent moisture(IM) which is usually

lost, into useful heat and helps in

▪ Reduction in consumption of coal by 2 – 3 %

▪ Reduction in un burnt in fly ash

▪ Reduction in un burnt in bottom ash

▪ Reduction in slag & clinker formation

▪ Reduction in stack emissions

▪ Reduction in ID Fan Power consumption

▪ Reduction in maintenance cost

▪ Continuity in the plant operation, hence improvement in

power generation

▪ HEAT LOSS IN POWER PLANTS

Moist Coal ∆ Dry Coal + H2O

▪ WORKING PRINCIPLE OF THERMACT

C + H2O THERMACT (CO + H2)

CO + ½ O2 ∆ CO2

C + 2H2 ∆ CH4


4. Innovative Projects Implemented (Contd.)

▪ Project 1: Achieving Coal Savings By “Reducing Unburnt in Ash” (Contd.)

Sr. No. Cost Benefit Analysis of Project 1 UoM Value

1 Coal Consumption per Day MT 680

2 Avg. Ash in Combined Fuel % 60

3 Ash Generated per Day MT 400

4 Unburnt Carbon at 4.5% per Day MT 18

5 FC in Combined Coal % 25

6 Equivalent Fuel Loss per Day MT 72

7 Value of Fuel Loss (Fuel cost @ Rs.2700/- per MT) Rs. Lakh 1.94

8 THERMACT Required per day (@ 1 kg for 15 tons of fuel) Kg 45.33

9 Price of THERMACT per kg Rs. 365

10 Cost Incurred in THERMACT per Day Rs. 16545

11 Unburnt Carbon Reduction by THERMACT usage (20%) MT 3.6

12 Equivalent Fuel Saved per day MT 14.4

13 NETT Savings per Day (14.4 MT x Rs.2700 = Rs. 38,880/-) Rs. 22,335

14 NETT Savings per Month Rs. Lakh 6.70


4. Innovative Projects Implemented (Contd.)

▪ Project 2: Replacement of Steam Soot Blowers with Sonic Horns in WHRB

▪ We were loosing lot of steam for soot blowing besides frequent undue failures of boiler tubes due of erosion by soot

blowing steam.

▪ Hence we have replaced the steam soot blowers with new technology sonic horns.

▪ We have saved in net Rs. 25.8 Lakhs with investment of Rs. 18 Lakhs. & achieved zero breakdowns.

▪ Project 3: Reject Coal fines & Washery reject Coal Used in Power Plant

▪ During the crushing of coal for DRI & SAF, fines are generated which are waste for them. Same are being used in power

plant.

▪ We procure Reject coal from washeries at lower price and use in power plants since its GCV is very less.

▪ Project 4: Process Control & Automation at Sponge Iron Plant

▪ At DRI plant, feed coal & injection coal ratio was 55:45% (i.e. 55% Feed Coal & 45% Injection coal). With this, specific

coal consumption was 1.35 MT per ton of sponge.

▪ After improvement in process, we changed feed coal ratio as 37:63% (i.e. 37% Feed Coal & 63% Injection Coal).

▪ With these changes, specific coal consumption has reduced to 0.91 per ton of production, and utilization factor /

campaign life improved, unwanted breakdowns were reduced.


5. Utilisation of Renewable Energy Sources

▪ Renewable Energy Generations & installed capacity in last three years

▪ We are having 550 kWp solar plant on plant boundary area.

▪ For solar plate performance improvement, we are cleaning solar plates on regularly basis, since

surrounding area is dusty.

▪ Also in process to implement, Nano technology coating for prevention of dust so that more power will

generated & frequency of cleaning is reduced.

587411

610181

575000

580000

585000

590000

595000

600000

605000

610000

615000

2016 - 2017 2017 - 2018

Solar Generation (kWh)

Solar Generation (kWh) Linear (Solar Generation (kWh) )

3.87%


6. Utilisation of Waste Material as Fuel

▪ Our Waste Management as follows

▪ Power Generation from

▪ By Product of Sponge Iron (Dolochar)

▪ Coal Dust from CHP & De-dusting System

▪ Bricks Manufacturing & Cement Plant

▪ Fly Ash, Bed Ash of Power Plant

▪ Granulated Slag of Ferro Plant

▪ Road Dust collected by Sweeping Machine

▪ Reusable Materials – As a Raw Materials

▪ Briquettes made by Collected Ferro Bag Filter Dust & reused in Furnace

▪ SMS Slag processed & recovered Metal parts are used in Furnace

▪ Hazardous waste stored in covered shed and sold only to MoEF/CPCB/CECB authorized party.


6. Utilisation of Waste Material(Contd.)

SOLID WASTE TOTAL QUANTITY (MT/Y)

FY 2015-16 FY 2016-17 FY 2017-18

A. From Process

Char/Dolochar 29688 28535 56109

Ferro Slag 39949.798 39744.538 71453.173

SMS Slag 19812.353 22622.24 25781.21

Accretion 624.02 590 620

Fly Ash 85494.94 92579 102852

B. From Pollution control facility

DRI ESP Dust 43417.16 31649 28529.724

DRI De-dusting Dust 1825 990 2250

Bag Filter Dust 2100.06 618.587 2310

C. 1 Quantity Recycled or Reutilized within the unit

Char/Dolochar 28721.9 26665.08 39323.02

DRI De-dusting Dust 1825 990 2250

Bag Filter Dust 1460 509.827 2310

C. 2 Sold

Char/Dolochar 1084.09 167.15 16785.98

Ferro Slag 38976.85 40597.15 72436.85

SMS Slag 20613.9 22545.78 25781.21

DRI ESP Dust 157.47 0 0

FLY ash 47733.23 93167.28 100743.89

Bag Filter Dust 1460 108.76 0

C. 3 Disposed

Accretion 624.02 590 620

Fly Ash 37761.71 0 0

DRI ESP Dust 43259.69 31649 0

Bag Filter Dust 640.06 0 0


6. Utilisation of Waste Material(Contd.)

▪ Waste Water Utilization:

▪ Total industrial water taken from CIBL (Govt. undertaking firm, surface water) – 4250 KL /Day And For

Drinking Purpose only 250 KL/Day from CGWA.

▪ We have installed Water flow meter at all the distribution system for daily monitoring of water utilization.

▪ Presently, our water consumption comes down to Avg. 4000 KL/Day running the full operation of the

plant by utilizing Waste water in respective areas.

▪ We are using waste water for plantation, Greeneries and Water sprinkler for dust suppression, ash

conditioning, Wet Scrapper, Slag Granulation.

▪ Arranged Soak Pit for Domestic waste and neutralization pit for chemical treatments.

▪ Also developed Roof top / Surface rain water harvesting.

▪ Garland drainage system has been implemented.

RECOVER

REDUCE

REUSE

RECYCLE

Reduction in Yearly Water Consumption per Production

Sr. No. Plant FY 2015-16 FY 2016-17 FY 2017-18

1 Sponge Iron 0.650 m³/T 0.526 m³/T 0.486 m³/T

2 Ingot/Billet 0.850 m³/T 0.859 m³/T 0.835 m³/T

3 Power 3.760 m³/MW/hr 3.970 m³/MW/hr 3.567 m³/MW/hr

4 Ferro Alloy 4.54 m³/T 3.00 m³/T 2.850 m³/T

5 Rolling Mill 0.652 M3/T 0.516 M3/T 0.450 M3/T


7. GHG Inventorisation▪ Installed Pollution Control Facilities like Waste Heat Recovery Boiler, ESP, de-dusting system, bag

filters.

▪ Introduction of THERMACT in boilers, our unburnt carbon % reduced from 6% to 3-3.5%

▪ Helped in Saving Natural Resources – by adopting Effective Reuse techniques.

▪ Reducing Energy Use in plant by implementing New Energy Efficient Technologies.

▪ Recycle all our industrial waste water

▪ Plantation of BEEMA Bamboo Plant (Energy Plantation) in 17 Acre area since it release oxygen into the

atmosphere 3 to 4 times higher than other trees. It removes 400 kgs of CO2 per year per plant.

Sr.

No.

Particulars FY 15-16 FY 16-17 FY 17-18

1 Metric Ton of CO2 by

Kwh Saving

2655 720 2717

2 Metric Ton of CO2 by

Coal Saving

0.00 101.26 127.84

3 By Waste Material

Utilization

772.02 679.35 1058.48

4 Total Emission of tCo2

Saving

3427 1501 3904

Note : 9.14 x 10-4 metric tons CO2/pound of coal

7.44 × 10-4 metric tons CO2/kWh

Sr.

No.

Year Scope 1

(CO2e) MT

Scope 2

(CO2e) MT

1 2015-16 1531614.8 173979.2

2 2016-17 1581302.8 177487.9

3 2017-18 1506519.4 180509.7


8. Green Supply Chain

▪ Green Supply Chain Management

▪ Green Supply Chain Management is a sustainable way to increase efficiency as well as a cost lowering

method for any kinds of term.

▪ It contributes greater towards improved financial performance.

▪ Increased use of resources, improved efficiency and reduced production cost.

▪ Guided for usage of less hazardous materials

▪ Improve production process from straight push to pull & recycle materials & Improved quality of

products

▪ Localize sourcing to reduce inventory

▪ In Case of Equipment Replacement – Prepared cost benefit analysis based on actual running parameters

collected by Auditors & Estimated parameters as per technical details.

▪ In Case of New Project – All design details of equipment's are verified by Auditors & after confirmation or

approval on equipment's purchasing started.

▪ We at Vandana Global enjoy working with Green Supply Chain Management

▪ We are benefitted by

1. Exploring alternate vendors for critical items

2. Encouraging & developing local vendors by providing helpful technologies etc.


1. Daily Monitoring System

▪ On daily basis, we are developing production report on plant wise

▪ Production report includes Consumption (Power, Raw Materials), Production & its quality.

▪ Detail discussion if any deviations on Specific Energy Consumption. Root Cause Analysis is being done by all

concern department head.

▪ Daily production, consumption, break downs or any major problems are reported through “What's App” & also

discussed in daily meeting

2. Daily & Monthly Review Meeting

▪ Daily Management Meeting is scheduled for one hour (2:30 pm – 3:30 pm), chaired by Plant Head & VP along

with all departmental HOD’s.

▪ Our costing department elaborates the losses & profits to HOD’s in daily costing meeting for better cost

control.

▪ Every divisional head conducts daily tool room talks, safety talks & review meeting with their respective

departments & seeks suggestions for betterment.

▪ Our Health department holds meeting & campus ensuring healthy for wealthy organization.

▪ Our safety department involves higher management to casual workers ensuring safe working environment, in

turn break free production.

▪ Once in Week & Monthly Meeting is chaired by Managing Director & Director along with Plant Head, VP & all

departmental HOD’s.

▪ Management organizes monthly meeting with employees along with HOD’s, contactors workmen, to improve

on co-ordination in between all staffs for better operating practices.

9. Team work, Employee Involvement & Monitoring


Daily Monitoring System (Contd.) : Power Plant & SMS Daily Report (Sample Copy)

9. Team work, Employee Involvement & Monitoring (Contd.)



3. Energy Conservation

▪ Management has taken more initiatives For improvement in Energy Efficiency & Conservation.

▪ Yearly allotted specific amount for implementation of Energy Saving projects.

▪ No any special approval / budget required for implementation of payback period less than two years on

recommended energy saving measures (Below 10 Lakh investment per project).

▪ Apart from energy department, designated person from each department of each division is responsible for

energy conservation

4. Energy Efficiency / Awareness Training Program

▪ Our internal audit team provides awareness cum training program during the measurements to concern dept.

end users.

▪ Energy Efficiency training program organized on regularly basis along with plant wise field training.

▪ A review meeting is scheduled among all these energy officials chaired by head of Energy department for

exploring new opportunities & monitoring existing efficiencies.

▪ By organizing these meeting cum discussion with concern HOD’s, we have created general awareness in

bottom line.


▪ Active Participation & Employee Involvement



5. Projects Implemented Through Auditors

▪ We are having separate team of Auditors.

▪ Auditors do the survey, inspection, analysis &

validation of energy flows being utilized in a

building, process, system to reduce the

amount of energy input without adversely

affecting the output(s) & quality.

▪ It starts from raw material to finish product &

waste generation-utilization

▪ Planning for implementation of energy saving

measures & re-validation



Orientation Meeting With Concern HOD’s

Data Collection & Process Understanding

Field Studies & Discussions on Results

Identification of Energy Saving Opportunities

1. No / minor investment

2. Mid term investment (payback : up to 2 Years)

3. Long term investment (payback : 2 – 4 Years)

4. Intangible

Implementation & Assistance

Monitoring

1. Renewable Energy Application

Assessment Study

On line training to concerned official(s)


5. Projects Implemented Through Auditors (Contd.)



5. Projects Implemented Through Auditors (Contd.) – Energy Monitoring Format


10. Implementation of ISO Rating

▪ Certifications

▪ We are having following certificates

▪ ISO 14001:2004

▪ ISO 18001:2007

▪ ISO 9001:2008

▪ We are in process to implement ISO 50001 & Green CO certification


▪ % Investment on Turnover & Energy Savings Achieved

0.18%

0.13%

0.19%

1.6

1.17

3.07

0.00%

0.02%

0.04%

0.06%

0.08%

0.10%

0.12%

0.14%

0.16%

0.18%

0.20%

0

0.5

1

1.5

2

2.5

3

3.5

FY15-16 FY16-17 FY17-18

% In

vest

men

t on

Ann

ual T

urno

ver

Ann

ual S

avin

gs (

Rs.

Cro

res)

% Investment on Annual Turn Over Annual Saving in Rs. Crores

10. Implementation of ISO Rating (Contd.)


Any other relevant information – Awards

39

▪ Awards:

▪ Urla Industries Association - Best

Open Plantation Award

▪ Bureau of Energy Efficiency - State

Level Energy Conservation Award

▪ Chhattisgarh State Renewable

Energy Development Agency

(CREDA) – State Designated Agency

– Sustainable Development Award

© Confederation of Indian Industry40

▪ Maintain air emission through appropriate & highly efficient equipment's within the norms as per CECB,

MoEF prescribes and regular updated accordingly i.e. ESP, Bag Filters, De-dusting system, Dense

plantation surrounding premises, Road dust collected by Sweeping Machine on regular basis.

▪ First time in Chhattisgarh introduced the Hybrid Bag filter in AFBC Boiler to maintain below 25 mg/Nm3

▪ All compliance and report are continue submitted on Govt. body as per consent conditions.

▪ Online CSEMS installed in stack to measure the Sox, Nox and PM , data transmitted to CPCB.

▪ We have maintain Zero Discharge and good Water management in all division, also develop rain water

harvesting to increase the ground water resource through roof top water harvesting.

▪ Maintain the water quality as per norms.

▪ We have obtain Hazardous waste authorization to collection, storage, disposal of used/spent oil Cat. 5.1

and sold only MoEF/CPCB/CECB authorized parties as per norms.

▪ No any litigation and complain by CECB/MoEF/CPCB and local community.

▪ We have taken benefits of Carbon Credit.

Any other relevant information – Compliances


▪ Certifications:

▪ Regular update, Periodic evaluation of the status of

legal requirements by Management.

▪ CG Factories act,

▪ Indian Boiler act,

▪ Air & Water (Prevention and control of pollution ) act,

▪ Hazardous & Other waste Management Rules,

▪ Indian Electricity Act,

▪ Central excise & custom act,

▪ Energy Conservation Act,

▪ Legal Metrology Act,

▪ Labor and Contract labor act,

▪ PF & ESIC

▪ BIS

▪ Wages Act & Bonus Act

▪ CG Shram Kalyan Nidhi Act,

▪ Explosive & Petroleum Act,

▪ GPA, PLI & WC

Any other relevant information – Compliances (Contd.)


▪ Company policies are displayed at various location in factory premises▪ Environment Health & Safety Policy

▪ Quality Policy

▪ Energy Policy

▪ Information Security Policy

▪ Integrated Management System Policy

Any other relevant information – Policies


▪ Achieved Bureau of Energy Efficiency target for PAT Cycle 1 & received ESCerts 19502 Nos.

▪ Received awards for

▪ Green Plantation by Industry Association.

▪ State level Energy Conservation Award by BEE.

▪ Sustainable Development Award by CREDA

▪ 33% of plant area covered by Greeneries. Apart from this, we planted Bamboo plants (Energy Plantation) in 17

Acre area.

▪ Vandana Global Limited, is a fully modernized and environment friendly plant.

▪ We are supporting CSR activities and also supported the local villages. Taken up excessive plantation in 4- 5

villages along with road side.

▪ Vandana Global Ltd is a continuously and actively involved in activities of the local village areas by funding for the

development of the village and institutional infrastructure.

▪ We have constituted a “VANDANA Shiksha and Kalyan Samity” for neighboring villages & Local body for health,

Education, Medical Camp to provide free medical check up, medicine, Ambulance facilities for better health.

▪ Frequently, we are organizing Blood Donation Camp, Health Checkup Camp

▪ Constituted Ganga Diagnostic Center for Medical check up & Niranjan Dharmshala as non profit organization

Any other relevant information – Achievements


Thank you

19th national award for excellence in energy management 2018€¦ · siltara industrial growth...

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