bhushan steel ltd. khopoli - knowledge platform...bhushan steel ltd. khopoli bhushan steel ltd is...

Our Products :-

• Precision Tubes

• Colour Coated Steel

• CR Steel/Strips/Sheet/Coil

• CR alloy Coated Strip/Sheet

• High Tensile Steel Strapping

• Hardened and Tempered CR

Steel Strips

•Large Dia. Pipe (Bare &

Coated)

Baseline Parameters Identified by

BEE Baseline

SEC (Yr-2014-15) 0.0367 mtoe /ton

Target SEC (Yr-2018-19) 0.0345

mtoe/ton

Bhushan Steel Ltd. Khopoli

Bhushan Steel Ltd is one of the prominent players in the

Indian Steel industry. Backed with more than 27 years of

experience, we are now India's 3rd largest Secondary Steel

Producing Company with an existing steel production

capacity of 5.6 million ton per annum.

As one of the largest integrated steel players in India, BSL is

a source for vivid variety of products such as Hot Rolled

Coil,CRCA,CRFH,Galvanized Coil and Sheet,Galume Coil

and Sheet,Color Coated Coils,Color Coated Tiles,High Tensile

Steel Strips,Hardened & Tempered Steel Strips,Precision

Tubes,HFW/ERW Pipe (API Grade),3LP Coated Pipes,Billets

and Sponge Iron.

2

Base line Audit

Aug-2011

3

Energy

Conservation

Cell

Formed

4

En-Con

Team

Formation

6

Optional Energy

Audit

&Implementation

Recommondation

8

Manadatory

Energy

audit conducted

dec,15 7

Detailed

Energy

audit

conducted

dec,13

Road

map

Won 9th State Level

energy conservation

award

Energy Policy

Renewed

(EnMS Policy)

Won National Energy

Conservation Award

award

8

Merged With

IMS (Integrated

Management

System)

Merged with

IMS Policy

Won 8th State Level

energy conservation

award

5

energy

policy

launched

1

Declared

D.C.

2010

9

EnMS

ISO 50001

Implementation

Training and awareness on Energy

Conservation Techniques Workshop & awareness session for ladies on energy

conservation in household appliances by PCRA

Painting and drawing competition Energy walk Oath ceremony

Creation of Awareness in the Employees- Energy Conservation Week

Prize Distribution

0

10

20

30

40

50

60

70

80

2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17

Budget

25

50

6570

25 25

75

Financial year

Rs

in l

acs

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

JSW Vasind

BSL Raigad

BSL Sahiba

badM/S M

ukund

Llyods Cha

ndrapur

MTOE/ton

0.0414 0.0345 0.0215

0.1086

0.6889

Budget Allocation Trend

SEC Benchmarking based on

PAT Notification

Year Saving

(lakhs of

Rupees)

Investment

(lakhs of

Rupees)

2010-11 250.81 24.42

2011-12 110.61 54.93

2012-13 149.492 65.39

2013-14 55.09 124.62

2014-15 286.28 27.88

2015-16 241.65 6.834

2016-17 452 74

Expenses & Savings

Energy Policy Yr.2012

Changed During EnMS

Yr.2015

IMS Policy Yr.2018

Projects Implemented in FY 2016-17

S.no Project Investment (Rs in lacs)

Saving (Rs in lacs)

Savings(KWh in

lacs)

Savings Fuel (Million Kcal )

1 Centac Compressor no.2 Efficiency improved by replacing Air end.

55 65 10.84 0

2 Waste Heat Recovery 15.1 309.52 3 569967

3 Energy saving through Drive & Motor control logic modification.

0 54 9 0

4 VFD Installation 0 5.72 0.95 0

5 Revamping of Steam Distribution Network 2.79 17.34 0 673.55

Centac no.2 Efficiency improved

by replacing Air end.

Total Energy Saving Implementation Cost

Rs. 65 Lacs Rs. 55 Lacs

Re-insulation of Ammonia

cracker furnace


Rs. 9.67 Lacs Rs. 05 Lacs



Use of waste heat for Chemical dryer

instead of RLNG burner at CCL



Use of waste heat for Product Sheet Dryer at CCL

Preheating Arrangement Before

Hardening Furnace


Rs. 29.63 Lacs Rs. 0.29 Lacs

DC Motor Running & Economy Field Current


Rs. 3.78 Lacs NIL


Rs. 5.72 Lacs NIL (Old Spare Available)

VFD Installation (02 nos)

Revamping of Steam Distribution

Network replacement of 32

Thermodynamics Steam Traps





Annealing area sump pump motors

controlled by using Level Switch

Energy Saving Projects Planned in FY2017-18

Sr.

No.

Description of energy efficiency improvement measure. Investment

(Rupees)

Verified

Savings

(Rupees)

Verified

Energy

savings

Units Remarks

1 Hot air steam dryer to be replace with direct hot air from

incinerator exhust blower stack.

100000 2,73,020 49,640 KWh Under Progress

13,31,520 701 Ton Under Progress

2 Chemical Coater burnner to be replace with direct hot air from

incineration stack (CCL Prod).

200000 51,14,003 8,370 mmBTU Under Progress

1,87,902 34,164 KWh Under Progress

3 New Drive instalation in Prime Oven Fume Recirculation Fan (CCL

Prod)

200000

2,43,667

44303 KWh Under Progress

4 TCV Installation at Brush tank (CCL Prod) 110000 2,66,304 140 Ton Completed

5 TCV Installation at Alkali tank (CCL Prod) 110000 2,50,958 132 Ton Under Progress

6 LED Light 150W (CCL Prod) 400 W HPSV Lamp (Shed light)

replaced with 150W LED (18Nos)

93600 43882 7978 KWh Completed

7 To maintain Air/Gas ratio by modification of firing system

(GP01Prod)

700000 0.960 0.866 mmbtu/mt Completed

8 Exhaust heat of pot furnace to Hot air dryer to maintain temp

(GP01Prod

100000 Under Progress

9 Optimisation of Unit consumption of Makeup pump by changing

pre-established system (Tube Div)

68000 1,68,480 28080 KWh Completed

10. Replacement of HPSV lamps with LED lamps (Tube Div) 540000 1,29,600 21600 KWh Planned

11 Planning for automatic off of mill utilities (Tube Div) 50000 1497916 249653 KWh Planned

12 Flue gases used in dryer to dry the strip, thus by eliminating steam

consumption in May'17 (GP02 Prod)

202000 2577207 16.71 Kg/mt Completed

13 Furnace tuned close to psychometric ratio and gap of entry seal

reduced (GP02 Prod)

Nil 3222828 0.049 Mmbtu/mt Completed

14 Thyristor control for NH3 cracker furnace (Power Plant Elect) 120000 114306 19051 KWh Planned

15 VFD for CT Fan (Power Plant Elect) 170000 641670 106945 KWh Planned

16 In Belling press Hydrolic system (Power Plant Elect) 2000 30000 5000 KWh Planned

17 Automatic control of substation outdoor lighting by photo sensor

(Power Plant Elect)

5500 32222 5723.2 KWh Completed

18 ENTRY HOT AIR DRYER BLOWER MOTOR (37KW) (GP1-Elect) 0 1080000 216000 KWh Completed GP1

19 SHED LIGHT (SHED NO 4) (GP1-Elect) 63700 38325 7665 KWh Completed GP1

20 SHED LIGHT (SHED NO 1 ) (GP1-Elect) 45000 10950 2190 KWh Completed GP1

21 HOT AIR DRYER (shed 2) (GP1-Elect) 55000 80788 17953 KWh Completed GP1

22 Chemical combustion blower motor(Motor stopped due to waste heat

recovery) (GP1-Elect)

Nil 189172 34395 KWh Completed

CCL

23 Hot air dryer #1 motor.( Motor stopped due to waste heat recovery)

(GP1-Elect)

Nil 273735 49770

KWh Completed

CCL

24 LED Light 150W (GP1-Elect) 93600 43882 7978 KWh Completed

CCL

25 Prime Oven Fume Recirculatin fan motor to be run with

VFD.Presently running with Star delta starter. (GP1-Elect)

200000 81000 18000 KWh Completed

CCL

26 LED Light 150W 135000 81000 16200 KWh Completed

27 Provided V.F. drive of trimmer-2 hdyraulic power pack system (GP1-

Elect)

49000 88128 17625 KWh Completed

28. PHF COMB. BLOWER-2 (GP1-Elect)

250000 241080 48216 KWh Planned GP2

29 HAD COMB. BLOWER (GP1-Elect) (GP1-Elect) 0 72000 14400 KWh Planned GP1

30 SHED LIGHT 400W (SHED NO 4) (GP1-Elect) 225000 136875 27375 KWh Planned GP2

31 SHED LIGHT 250W (SHED NO-1,2 &5) (GP1-Elect) 450000 109500 21900 KWh Planned

32 Hot air dryer #1 motor (22KW) to be run with VFD(Due to use of flue

gases for drying motor is completely stopped.Hence VFD not connected

(GP1-Elect)

100000 77143 14026 KWh Planned GP1

33 V.F. Drive 11kw in trimmer -1 power pack hydrolic system (GP1-

Elect)

49000 88128 17625 KWh Planned

34 LED Light 150W (GP1-Elect & API) 2835000 1336000 205538 KWh Under Progress

35 Refurbishing of furnace insulation (NCRM Annealing) 550000

1858216 2667 mmbtu Planned

Flue gases used in dryer to dry the strip, thus by eliminating steam consumption in

May'17 (GP02 Prod)

Steam Line cut off & Flue exhaust gas

used in degreasing dryer

HAG exhaust flue gases used in

SPM dryer.

Entry Seal Gap reduced from

190 mm to 141 mm

Exhaust gas used in chromic

dryer

Furnace tuned close to psychometric ratio and gap of entry seal reduced

Total Energy Saving

Rs.25.77 Lacs

Implementation Cost

Rs.0.20 Lacs

Total Energy Saving

Rs.32.22 Lacs

Implementation Cost

Nil

ELIMINATION OF HOT AIR DRIER AT CCL, HEAT RECOVERY FROM INCINERATOR

EXHAUST FLUE GAS

ELIMINATION OF LNG CONSUMPTION AT

CHEMICAL DRIER ( CCL)



ELIMINATION OF HOT AIR DRIER AT

DEGREASING GP02





●Previously we were using Unikleen 68 B which was in

powder form & require heating of solution at 70 to 80 °C.

●Currently we are using Unikleen 70 L which is in liquid form

& can be used at roomtemperature.


Rs. 7.52 Lacs Rs. Nil

Eliminationof Steam usage

Degreassing section of GP-02

line

Shed Lights of conventional type

(400/250watts)Replaced With LED

Lights (150 Watts, 460 no.s)


Rs. 18 Lacs/Year Rs. 39 Lacs

Projects Implemented in FY 2015-16

Sr. no.

Project Investment (Rs in lacs)

Saving (Rs in lacs)

Savings(KWh in lacs)

Savings Fuel (million Kcal )

1 VF drived used in plant 5.570 62.634 14.465 0

2 Energy Saving through PLC logic modification

0 6.928 1.600 0

3 Condensate recovery from RFO yard 1 1.620 0 73.04

4 Lighting Projects 0.264 0.296 0.069 0

5 Fine tunning & Setting A/G ratio 0 168.454 0 4149.824

6 Use of Smaller size Lovejoy coupling 0 1.715 0.396 0

Energy Saving Recommendations/Scope of Major Energy Saving Options in

External Energy Audit- Bedmutha

Audit Culture shows our committment

About Energy Conservation

Base Line Energy Audit-Yr.2010

Optional Energy Audit-Yr.2013

Steam Walk Through Audit-

Yr.2014

MEA-yr.2015

Pump Audit-Yr.2016

Steam Detailed Audit-Yr.2017

Insulation Audit-Yr.2017

Air Distribution Audit-On Going

MEA-Praposed April2018

Water Balance Audit-Future

Planned

Harmonics Audit-Future Planned

Project 1 : Installation of solid waste based hot water generation system

Total Energy Saving Implementation cost

Rs 5,77,336 Rs 5,47,000

Previously Implemented Projects


Rs 1,13,81,076 Rs 36,00,000

Project 2 : Installed KVX system on gas fired boiler to enhance the overall

efficiency by 10% by facilitating better combustion.

C C

C H

High fuel consumption

High CO emissions Before

Modification

After

Modification

C C

C H

Fuel consumption

reduced by 10%

CO emissions reduced

by 30%

Strong C-C &

C-H bond

Weak C-C

& C-H bond

SEC (Electrical + Thermal) in TOE/tonne of Product without

Normalization

Year

SEC

TOE/tonne

(of

Product)

Production

(Mt)

Consumptio

n

MKcal

2010-11 0.0397 1034500 410277

2011-12 0.0399 1078824 430681

2012-13 0.0413 1086367 448429

2013-14 0.0405 983041 398434

2014-15 0.0364 753837 274212

2015-16 0.0329 920604 302708

2016-17 0.0324 977670 316926

0.0320

0.0340

0.0360

0.0380

0.0400

0.0420

2010

-11

2011-

12

2012-

13

2013

-14

2014

-15

2015-

16

2016

-17

0.03970.0399

0.0413

0.0405

0.0364

0.0329

0.0324

TO

E/t

on

ne

Specific energy consumption (TOE/tonne of product)

Plant Capacity Utilization Except Large Dia Pipe Plant After

PAT Cycle-I

0%

20%

40%

60%

80%

100%

2014-15

2015-16

2016-17

Capacity Utilization

70%

85%92%

Financial year

Financial year

Total Plant

Capacity

Total Production

Capacity Utilization

2014-15 1040000 722954 70%

2015-16 1040000 884886 85%

2016-17 1040000 953728 92%

Installation of Polycrack system with 50 kg I/P Charge of polythene & plastic

product & produce diesel , gas & carbon


Rs 5,34,000 Rs 12,00,000

Future Plans For Energy Conservation

Planning to put industrial solar water

heating system of capacity 30000LPD

at 80degC . Heated water will go to

boiler in place of normal feed water

Planning to extend our capacity of solar

water heating system with 8000LPD for

colony

Planning to install Solar PV plant of

capacity 500KWp-1MWp in

forthcoming years

Planning to put Heat Pump for heating coolant water of mill up to 65 degC which will

replace existing heating system of steam heat exchanger and will save 40% of energy.

Expansion Valve

Ambient Air

Inlet

Cool

Air Outlet

Cold Water

Inlet

Hot Water

Outlet

Air Source Heat Pump

Water Heating System

Compressor

Planning to install Fuel Enhancer Kit in our company vehicle to save fuel

10-40%

Co-generation WHR Boiler On Power Plant

Inlet

flue gas

Steam

generatio

n

Exhaust

Enviormental projects & New Technologies Implemented

Clean Development Mechanism

The Clean Development Mechanism (CDM), defined in Article 12 of the KYOTO Protocol,

allows a country with an emission-reduction or emission-limitation commitment under the

Protocol to implement an emission-reduction project in developing countries. Such projects

can earn saleable certified emission reduction (CER) credits, each equivalent to one tonne of

CO2, which can be counted towards meeting Kyoto targets.

The mechanism stimulates sustainable development and emission reductions, while giving

industrialized countries some flexibility in how they meet their emission reduction or limitation

targets.

Bhushan Steel Ltd has registered 2 projects under UNFCCC with consultation of Frenz

Greenearth Technologies Pvt Ltd totalling a prospective Certified Emission Reduction (CER)

capacity of around 18000 T CO2 per year. Projects are:

1.UNFCCC CDM Project No-.8802: 24 MW Power Plant .For

reference:http://cdm.unfccc.int/Projects/DB/TUEVSUED1355561731.08/view

2.UNFCCC CDM Project No-.8801: Industrial Boiler.For reference:

http://cdm.unfccc.int/Projects/DB/TUEV-SUED1355560177.97/view

Bhushan Steel Ltd has actively maintained its GHG inventory according to ISO 14064-

1:2006(certification under process).

The ISO 14064 standards (published in 2006 and early 2007) are the most recent additions to the

ISO 14000 series of international standards for environmental management. The ISO 14064

standards provide governments, businesses, regions and other organisations with an integrated set of

tools for programs aimed at measuring, quantifying and reducing greenhouse gas emissions. These

standards allow organisations take part in emissions trading schemes using a globally recognised

standard.

CDM (Clean Development Mechanism) is also an integral part of GHG inventory managment and we

are active in that field also.

GHG Inventory Development

Multi Effect Evaporator Reverse Osmosis Plant

TCR for Harmonics Filtration &

Power Factor Correction

Assessed P.F. Unity and Load Factor

94% in MSEDCL bill

0.998 0.94

28

Electrolytic Cleaning Line Rain Water Harvesting

Acid Regeneration Plant Organic Waste

Compositing

Re-Generative unit

at API-1

BSL Won 8th State Level EC Award

Year 2011-12

BSL Won 9th State Level EC Award

Year 2012-13

BSL Won NECA Award Year 2015-16

CREDITS

Mr. KD Sahni-Plant Head

Mr. B.Nahar- Divisional head Wider CRM

Mr. Padam Agrawal -Divisional head commercial

All production and electrical,mechanical maintenance

department

THANKS

bhushan steel ltd. khopoli - knowledge platform...bhushan steel ltd. khopoli bhushan steel ltd is...

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