national award for excellence in energy management 2018 · 2018-09-13 · company profile &...

31-08-2018 | tk ES India

thyssenkrupp | Steel | Electrical Steel

National Award for Excellence in Energy Management 2018

thyssenkrupp Electrical Steel India Private Limited; NashikPresenting Team:Vinayak Salunke: Head- Energy, Electrical, Instrumentation & Systems

Shravan Kumar : Asst. Manager, Utility & Mechanical Maintenance

CII AWARD 2018

Company Profile & Standard Production Process Flow

▪ Electrical Steel is used in energy efficient electrical appliances▪ CRNGO steel is used in rotating machines like motors, generators▪ CRGO steel is used in transformers, rectifiers

tkES makes Energy Efficient Steel with low core loss

Hot Rolled Coil

Tunnel Furnace

Box Annealing

Box Annealing

Side Trimming & Slitting

Side

Trimming

& Slitting

Laser

Scribing

Heat Flattening

and Coating

Pickling

Cut to Length

Tandem Annealing,

Decarburizing & Coating

Cold

Rolling

Pickling

Cold

Rolling

Decarburizing

& Nitriding

MgO

Coating

Non Grain Oriented

Grain Oriented

P

A

C

K

I

N

G

HR Pickled &

Annealed Coils

CII AWARD 2018

Increase in SEC is due to forward and backward integration

0

100

200

300

400

0

600

1,200

1,800

'15-16 16-17 17-18

Electrical

+Thermal

Production

kW

h / M

T

‘000 M

T

Product Consumption normsProduct mix (%)

15-16 16-17 17-18

CRNGO 83 78 65

CRGO CRNGO + 44 % 17 22 35

Capacity Utilization (%) 54 45 37

1. Overall Specific Energy Consumption trend (SEC)

CRGO trials CRGO trials & new processes

Reasons for increase in SEC by 27% :-1. Trials of CRGO at Tunnel furnace

2. Addition of new process lines (Nitriding & decarb, MgO coating and Laser line) in Jan.18

3. Increase of CRGO production from 17 to 35% which has high SEC

4. Production volume decreased by 33%

CII AWARD 2018

Increase in SEC is due to change of product mix and lower production volume

0

75

150

0

600

1,200

1,800

'15-16 16-17 17-18

Thermal

Electrical

Production

kW

h / M

T

‘000 M

T

1. CRNGO- Specific Energy Consumption trend (SEC)

Reasons for increase in SEC by 30 %:-1. M Si production increased from 43 to 50%

2. H and VH Si production increased from 17 to 32%


Product

grade Consumption norms

Product mix (%)

15-16 16-17 17-18

L Si L Si 40 28 17

M Si L Si + 7% 43 47 50

H Si L Si + 44% 11 10 14

VH Si L Si + 47% 6 15 18

CII AWARD 2018

SEC is reduced by 13 % in 17-18 as against 16-17

0

5

10

15

20

25

0

600

1,200

1,800

2,400

'15-16 16-17 17-18

‘000 M

T

kW

h / M

T

1. CRGO- Specific Energy Consumption trend (SEC)

CRGO trials

Reasons for increase in SEC by 3.8% is due to CRGO trials at Tunnel Furnace

Thermal

Electrical

Production

CII AWARD 2018

2. Equipment wise comparison Specific energy consumption (16-17) :kWh/MT

Cold rolling mill Continuous Annealing

-2%

tkIsbergues

tkESIndia

Gap(Target)

-5%

tkIsbergue

tkESIndia

Gap(Target)

Box Annealing Heat flattening & coating

21%

tkBochum

tkESIndia

Gap

-12%

tkBochum

tkESIndia

Gap(Target)

CRNGO :

tk Bochum, Germany plant

CRGO:

tk Isbergues, France plant

CII AWARD 2018

‘000 M

T/m

on

th

Reasons for higher SEC by 3.9 %:-1. Higher production volume effect.

2. Three separate lines for producing each grade

(L, M & H Si) as against one common line at India.

3. Compact furnace design

SEC is higher due to lower production volume at tkES

2. Comparison of energy consumption norms for products

0

2

4

6

8

10

12

0

300

600

900

1,200

1,500

16-17 16-17

tk Germany tkES India

kW

h /

MT

Rolling mill + Annealing + Coating + Slitter Box Annealing + Coating

0

2

4

6

8

10

12

0

300

600

900

1,200

1,500

1,800

16-17 16-17

tk France tkES India

kW

h / M

T

‘000 M

T/m

on

th

Reasons for higher SEC by 3.7%:-Higher production volume effect.

CRNGO CRGO

Thermal

Electrical

Production

CII AWARD 2018

2. Roadmap of energy conservation measures for achieving gap:

Sr./

No.Projects

Ann. Saving

Lakhs.Investment Payback

kWh Rs. Lakhs Rs. Months

1 Fuel change from Furnace oil to LPG at one boiler 8 29 80 33

2Reduction of electrical consumption from 145 to 138

KWh/MT at Mill1 by optimizing idle running & use of VFDs3 23 7 3

3Reduction in steam header losses from 529 to 476 MT per

month by isolation of header of idle equipments5 14 1 1

4

Reduction of electrical consumption of Nitrogen gas plant

from 0.71 to 0.67 kW/Nm3 by improving repair quality of

PSA valves

1 9 2 3

5Reduction of steam consumption from 76 to 72 Kg/MT at

Pickling Line by optimising start up time & water flow1 4 1 3

6Replacement of 100 shed lights of HFCL line from 250 W

HPSV to 90 W LED1 4 6 18

7 Insulation of Clean Oil Tank at Mill1 & Mill2 1 3 2 9

Total 21 86 99 14

With implementation of above measures, overall SEC is expected to reduce by 42 kWh/MT

and 800 tCO2 emission reduction

CII AWARD 2018

Sr./

No.

Project with no financial investment

Ann. Saving

Lakhs

kWh Rs.

1Reduction of total gas flow from 444 to 350 m3/hr at TADL by optimising

sealing system7.7 23.8

2Reduction of LPG consumption from 37 to 29 Kg/MT at HFCL by optimising

temperature cycle & exhaust gas flow.10.3 23.5

3Reduction of specific furnace oil Consumption at boiler from 91 to 85.8

Ltrs/MT by optimising boiler operations on idle days & reducing cold starts 13.8 21.3

4Reduction of steam consumption at HFCL from 231 to 210 Kg/MT by

optimising water flow6.8 8.4

5Reduction of electrical consumption in ETP from 1.8 to 1.6 kWh/KL and

Boiler from 14.8 to 13.3 kWh/MT by auto controls of pumps and blowers1 5.9

6 Switching off one return & supply water pumps of scrubber at HFCL 0.4 2.7

7Reduction of electrical consumption on idle days at TADL by switching off

one auxiliary transformer (TR3-6) of 2 MVA 0.06 0.4

8VFD (110 kW) frequency is reduced from 42 to 30Hz by 100% opening

damper during start up of combustion air blower at ARP0.01 0.1

Total 40 86

3a. Energy savings projects implemented in 2015-16

CII AWARD 2018

Sr./

No.

Project with financial investmentAnn. Saving



9Installation of waste heat recovery system on burner

exhaust gases to heat water for scrubber at TADL7 11 41 45

10 Replacement of 200 FTL of 50 W with18 W LED tube light 0.6 3.5 1.6 5

11 Replacement of MG set with AC drives at CTL1 0.4 2.6 112 517

12 Installation of energy savers in Air conditioner at BAF 0.09 0.6 0.2 4

13Installation of VFD (30 kW) for combustion air blower V -30

at ARP0.08 0.5 1 22

14Switching off one alternate lamp at boundary wall lighting

after 10.00 PM (Qty: 22 nos.)0.01 0.03 0.02 8

Total 8 18 156 103

3a. Energy savings projects implemented in 2015-16

With implementation of 14 measures & mitigated 1,870 t CO2 15-16

CII AWARD 2018

Sr./

No.

Project with no financial investment

Ann. Saving

Lakhs

kWh Rs.

1 Reduction of transformer voltage at Gas plant & TADL:3 nos. 4.0 20.4

2Reduction in electrical consumption in utility from 66 to 62 kWh/MT by auto

controls of lighting & VFD for pumps1.5 7.7

3Twelve Jet cool fans (22 kW each) are switched off after 8 hours from removal of

hydrogen during shutdown at TADL furnace0.5 3.4

4 Installation of 75 kW VFD for Scrubber dryer blower at HFCL 0.4 2.5

5 Reduction in frequency to 40 Hz during line run in ATS dryer 45 kW VFD at HFCL 0.3 1.9

6 Agitator used instead of compressed air in poly dosing tank at ETP 0.3 1.6

7Reduction in electrical consumption from 17 to 14 kWh/MT at BAF by optimising

base, circulation and cooling fan speeds 0.2 1.4

8 Switched off compressed air wiper after quenching tank during line stop at TADL 0.1 0.8

9Replacement of 80 shed lights of CRS#4 & 5 from Sodium vapour (250 W) with

Metal Halide lights which are removed from CRS#1 & 2 (150 W). 0.07 0.5

10Common Combustion exhaust blower for eight annealing bases is operated in

close loop control with pressure feedback at BAF. 0.07 0.4

11 Use of additive in compressor oil of refrigerant unit (Coating chemical storage) 0.01 0.04

Total 7.4 41

3b. Energy savings projects implemented in 2016-17

CII AWARD 2018

Sr./

No.Project with financial investment

Ann. Saving



12

Reduction of specific furnace oil consumption at Boiler from

85.8 to 83 Liters/MT by optimising boiler operations on idle

days & reducing cold starts

3 8 10 16

13Replacement of 200 shed lights of Mill1, TADL, CRS from

150 W Metal Halide to 90 W LED.0.5 3.3 15.2 55

14Replacement of 110 shed lights of Pickling from Sodium

vapour (250 W) to Metal Halide (150 W)0.45 2.8 0.1 1

15Installation VFD for agitators at coating chemical storage

tanks at TADL0.22 1.4 0.1 1

Total 4.17 15 25.4 20

3b. Energy savings projects implemented in 2016-17

With implementation of 15 measures & 850 t CO2 Mitigated in 16-17

CII AWARD 2018

3c. Energy savings projects implemented in 2017-18

Sr./

No.Project without and with financial investment

Ann. Saving



1Reduction of electrical consumption on idle days at TADL,

Mill1, BAF, MBAF, HFCL, Gas Plant, ARP and Boiler by

optimising start up time

1.52 10.2 -- --

2 Reuse of vent N2 from liquid N2 tanks. 0.37 2.5 -- --

3 Compressed air pressure reduced from 4.9 to 4.6 kg/cm2 0.07 0.9 -- --

4Reduction of fresh water consumption by arresting

leakages of storage tanks0.03 0.3 -- --

5Installation of VFD for cooling water supply pump (30 kW)

for utility air compressor, Pickling and HRS at Cooling

tower no. 1

0.38 2.6 1.5 7

6Replacement of 50 shed lights of Mill2 bay from 250 W

Metal Halide to 90 W LED0.35 2.3 3.8 20

7Installation of VFD at cooling water supply pump (30 kW) to

Mill2, HFCL, Tunnel & Slitters at Cooling tower no.3.0.12 0.8 1.5 22

Total 2.84 20 6.8 14

250 t CO2 Mitigated in 17-18

All energy savings projects committed last year are implemented in 17-18.

CII AWARD 2018

3c. Reduction of electrical consumption on idle days❑ Equipments are operated as per demand from market which results in idling of equipments by 16 days per month

❑ Timely control of electrical equipments are important to optimise electrical consumption during non productive period

✓ Improvement done in line shut down procedures by providing optimum sequence and automations

✓ Optimization of switching off time for auxiliary equipments during shutdown

Equipments Run time optimisation by switching off:Cold rolling Mill1 &2 Auxiliary equipments are switched off after 10 minutes during shutdown

Tandem Annealing &

Decarb Line (TADL)

We have optimized run time Tandem Annealing & Decarb Line by auto

Switching off jet & slow cool blowers, circulation blowers, combustion & exhaust blowers

auxiliary transformers

Batch Annealing (MBAF) Transformers (2 x 3.5 MVA) and cooling water supply pump within one hour after shutdown

Batch Annealing (BAF) Exhaust blower and cooling water supply pump within one hour after shutdown

Acid Regeneration plant Circulation pump, exhaust fan and combustion blowers after 3 hours

EquipmentBefore (16-17) After (17-18) Diff. Annual saving

Idle days/ month KWh/day Idle days/ month kWh/day kWh/day Lakhs kWh Lakhs Rs.

Mill-1 16 1,017 17 900 118 0.25 1.6

Mill-2 23 1,067 19 767 300 0.70 4.7

TADL 16 687 15 465 221 0.40 2.7

MBAF 5 226 5 193 33 0.02 0.1

BAF 14 67 15 48 19 0.03 0.2

ARP 24 49 27 12 37 0.12 0.8

Avg. 16 519 16 398 121

Total 1.52 10

Achieved saving of 10 Lakhs Rs. without any financial investment

Doc. No.:tkES:HSE:PRD 01

Rev. No. : 01

Eff. Date : 14.06.2017

SOP No.63Page 1 of 1

1 :

2 :

3 :

4 :

5 Procedure :

Sr. No. Responsibility

1 Operator / Shift In-charge






7 EMD00


9 MMD

10 P&M00


Inform to EMD MILL,ETR ,DTR & Pay off drive including its

cooling blower,witched off if Mill stop for more than 01

hour

Main air valve on DTR panel to be made off

Inform to MMD Mill compressor to be switched off if Mill

stop for more than 01 hour.Inform to LCSS for capacitor bank to be made off within

10 minutes (maximum) from Mill stop (shutdown more

All packing instruments to be kept in tool box in ETR

Lift all coolant below suction level from DOT tank to COT

Responsibility Shift In-charge / Operator

Cross reference ISO : 14001, OHSAS : 18000 & ISO50001

Guideline

After finishing the last coil keep packing below BUR and

COT pump suction & delivery valve to be closed.

HP and LP hydraulic power packs, COT & DOT pumps and

Fume exhaust blower are to be switched off within 10

minutes (maximum) from Mill stop (shutdown more than

one hour) during Mill shutdown.

Vaccum filter motor,magnetic separator,agitator in COT

tank ,hood lights to be to be switched off within 10

Both side agitator to be made off & only centre agitator

to be made on within 10 minutes (maximum) from Mill

Scope PRD-01

STANDARD OPERATING PROCEDURES

Standard procedure for Mill shut down

Purpose Procedure for mill shut down

CII AWARD 2018

3c. Variable Speed Drives for cooling water supply pumps

❑ There are three cooling towers and nine cooling water supply pumps

❑ There is a variable load on five pumps due to batch processes and staggered production

❑ Variable speed drives were already installed at 3 applications (Cold Rolling Mill1, Batch Annealing furnaces)

❑ Installed two variable speed drives on pumps supplying cooling water to multiple equipments in Sep.17 & Nov.17

30 kW VFD @ CT-1

Pump

@ 120 m3/hrBefore- kWh After- kWh Diff- kWh

Annual Savings Investment Payback

Lakh kWh Lakh Rs. Lakh Rs. Months

P3-1 CT-1 24.7 17.8 6.9 0.38 2.6 1.5 7

P12-2 CT-3 24.2 22.0 2.2 0.12 0.8 1.5 22

Achieved saving of 3.4 Lakhs Rs. and payback of 14 months

Pu

mp

@ C

T-1 HR Slitter

Pickling

Utility air compressors P

um

p @

CT

-3

Cold Rolling Mill#2

Tunnel Furnace

HFCL

CR Slitter # 4, 5

Mesh Belt Furnace

30 kW VFD @ CT-3

CII AWARD 2018

Implemented for the first time in India for curing of MgO coated steel coils

Warming Air Annual Production

(MT)

Annual savings

Lakhs m3/annum LPG - MT Lakhs Rs. t CO2

347 35,000 163 62 507

4. Innovative project: Infrared curing of Magnesium Oxide coating on CRGO coils (Jan.18)

❑ To achieve uniform and controlled curing, 16 infrared burners are installed with LPG as a fuel.

❑ Instead of warming the air like other conventional heaters, infrared heaters heat objects directly in their paths.

❑ Infrared heaters use a substantially lower amount of energy by 5-10 % than conventional heaters.

❑ The infrared rays emitted are easily absorbed by the coated strip which results into instant curing.

❑ This concept is taken from group company. They are having ceramic burner and we have put metal fiber burner.

Before

This concept can be implemented for drying application of various types of coatings on flat steel.

CII AWARD 2018

We consider EE and environment improvement during revamp and new projects

5. Utilisation of renewable energy sources:

RO PlantSr./

No.Projects

Ann. Saving



1Installation of 9 translucent sheet on Boiler shed roof

(Jan.16)0.04 0.3 0.54 21

2Installation of 4 translucent sheet on RO plant shed roof

(May 16)0.02 0.1 0.24 23

3

Installation of 3 powerless ventilator fans at RO plant

(May 16)0.03 0.2 0.3 20

4Installation of 30 translucent sheet on ARP shed roof

(Jan.17)0.07 0.5 1.8 47

5 Installation of 6 powerless ventilator fans at ARP (Jan.17) 0.05 0.4 0.6 20

6Installation of 22 translucent sheet on BAF shed roof

(Mar. 18)0.35 2.5 1.32 6

Total 0.56 4 4.80 15

CII AWARD 2018

6. Utilization of waste: Use of excess vent Hydrogen gas as a fuel

❑ The consumption of Hydrogen gas in the plant is less than the minimum generation capacity i.e. 240 Nm3/Hr. This depends on number of furnace in use as per market demand. The excess hydrogen is being vented into atmosphere to maintain plant operations. Valuable energy is thus being vented.

❑ We had installed new control scheme so that vent Hydrogen is used in a reformer burner as a fuel to save main LPG fuel.

Excess Hydrogen used as a fuel

Year NM3 MkCal15-16 60,041 154

16-17 51,853 133

17-18 76,219 196

Average 62,700 161

Resulted in LPG saving of 14.7 MT/annum (5.6 Lakhs Rs./annum.)

CII AWARD 2017

❑ Started Management Programme on paperless office from Jan’16

❑ Department wise data analysis of hard documentation : Total 909 records

❑ Only legal documents maintained in hard format : 106 records

❑ Periodic review of implementation

Year Hard copies eliminated Saving Lakhs Rs.

16-17 3,691 0.43

17-18 2,382 0.33

6,073 0.76

Avoided cutting of new trees and taken a step to improve operational efficiency

Measures implemented:-

▪ Elimination of duplicates or unnecessary copies: 59 records

▪ Converted to soft formats like excel, word and pdf: 658 records

▪ Common printers with Xerox machines

▪ Development of software systems : 86 records (Few systems as below)

➢ Fault Tree Management (FTM) software system to eliminate log books

➢ Training attendance system

➢ System for registering suggestions from employees

➢ System for canteen services to avoid coupon printing

6. Environmental project: Paperless office

CII AWARD 2017

6. Environmental project: Rainwater harvesting

Fresh water saving of 23,000 KL which is equivalent to two months consumption

Average rain fall at this location is 2,750 mm/year

Year Rain water collection and used in process (KL)

15-16 1,789

16-17 18,203

17-18 23,398

Pump house roof Rain water collection pitWTP & Boiler roofGas plant roof

CII AWARD 2017

6. Specific fresh water consumption trend

3.22.7

2.4

0

100

200

300

400

0

1

2

3

4

5

15-16 16-17 17-18

25 %

Reduction of Specific fresh water consumption by 25 %

Water conservation measures:-

❑ Installation of RO and MEE plant (53,000 KL/annum reused: Zero discharge plant)

❑ Rain water collection

❑ Drip irrigation for gardening:-1.5 Kms.

❑ Underground hydrant replaced with above ground:- 4.5 Kms.

❑ Sewage treatment plant:- 200 KL/day (3,800 KL/annum reused)

Fre

sh

Wate

r

KL

/MT

Pro

du

cti

on

‘0

00 M

T

KL/MT

Production

CII AWARD 2017

We report GHG data to tk group’s headquarters every year

tCO2/Kg

of product

Production

7. GHG Inventorisation (Scope 1, 2 & 3)

0

100

200

300

400

0.00

0.20

0.40

0.60

0.80

'15-16 16-17 17-18

tCO

2/K

g o

f p

rod

uct

‘000 M

T

CRGO trial

CRGO trials &

new processes

ProductNorms: tCO2/kg of

product

Product mix (%)

15-16 16-17 17-18

CRNGO 83 78 65

CRGO CRNGO+127% 17 22 35

Reasons for increase in GHG emission by 35% due to forward and backward integration :-1. Trials of CRGO at Tunnel furnace

2. Addition of new process lines (Nitriding & decarb, MgO coating and Laser line) in Jan.18

3. Increase of CRGO production from 17 to 35% which has high SEC


CII AWARD 2017

Consolidated GHG data is published on group website. https://www.thyssenkrupp.com/en/company/sustainability/environment/environmental-protection/

7. tk Group’s Public disclosure of GHG Inventorisation

CII AWARD 2017

8. Green supply chain (GSC): Awareness creation in suppliers and customers

VENDOR REGISTRATION FORM-ExternalName of the vendor :

Address for correspondence :

City : Pin code : State :

Tel no.

Fax no.

E-mail :

Website :

Name of the parent/ principal company

Nature of business () Manufacturer

() Trader

() Authorized dealer*

() Service provider

* Attach a copy of dealership certificate

Business with other THYSSENKRUPP Group

companies

Y/N

Financial details of the firm

Are you a Micro / Small / Medium / Large Enterprise

as defined in MSME Development Act, 2006? (If yes,

please send Certificate of Registration and along with

a Certificate of Chartered Accountant.)

Y/N

Is the firm ISO 9001:2000 certified ? Y/N

When was the last ISO audit conducted ?

Is the firm ISO 14000 Certified? Y/N

Is the firm certified by any other quality certification

institutes , specify if any Y/N

Is your firm following green practices ? Y/N

What are the major practices ? Please specify

*Attach copy of respective certificates Of audit

❑ Vendor registration based on GSC:-

We are collecting information about green practices being followed by them and are allotting 5% weight age for the same

244 vendors/service providers are trained

Year No. of persons Hours

15-16 67 134

16-17 55 110

Total 122 244

❑ Training of vendors/service providers:-

Create awareness and build capacity onenvironmental sustainability covering energy,water, materials, waste and GHG to facilitatein greening the supply chain

Category of vendors/service providers trained:-

▪ Panels, Drives and Spares suppliers

▪ Raw material suppliers

▪ Consumable suppliers

▪ Fuel suppliers

▪ Transporters, etc.

CII AWARD 2017

❑Raw material for manufacturing CRGO are imported from France which comes on wooden pallets, Met wrap plastic and air bag packing.

❑Earlier these wooden pallets and plastic were sold in scrap as size of pallets were big.

✓ Started re-using these waste wooden pallets by increasing coil weights since Dec’15 ,

✓ Plastic sheet for packing of finished CRGO coils in place of galvanized metallic sheet since Jan’17.

✓ 2300 air bags are reused for protection of finished coils during transit

Year Fresh wood saving MT Saving Lakhs Rs.

16-17 31 6

17-18 148 20

Plastic reused MT

17-18 2.8 7

Avoided cutting of new trees, generation of new plastic and saved Rs. 27 Lakhs per annum.

Pallet Size: 1250 x 1250 mm Weight: 46 Kgs.

8. GSC measures: Reuse of wood & plastic for packing of finished Goods

Met wrap (Poly propylene) sheet : 3 mm thick

CII AWARD 2017

~3 tCO2/annum CO2 emission is eliminated:

➢ Reduced Nashik to Plant number of trips

from 5 to 2 per week

➢ Total trips reduced per annum: 144 nos.

➢ Average / day running of vehicle : 60 kms.

➢ Savings per annum : 8,640 kms.

➢ Diesel saved per annum @ 8 kms. / liters

: 1,000 liters (Worth one lakhs Rs.)

8. GSC measure: Milk run system for collection of purchase items

Before : C class items from different suppliers are delivered to plant daily

After: C class items from different suppliers are collected at one place and

then delivered to plant twice per week.

tkES plan

t

tkES plan

t

CII AWARD 2018

9. Long term targets for Sustainable Growth

Commitment to reduce energy intensity and emissions, discharge and waste generation by

0.5 to 1% every year for ten years

Key H

ighlig

hts

of C

ode f

or

Ecolo

gy

Reduce specific consumption of energy, water and GHG emission by 1% every year

Reduce specific generation of Hazards waste & depletion of natural capital by 0.5% every year

Increase use of renewable energy and recyclables by 0.5% every year

Increase use of harvested rain water by 0.2% every year

Incorporate Life cycle assessment & Green purchase policy

Promoting Product stewardship

CII AWARD 2017

❑ Appointment of Energy Manager

❑ Revised IMS policy for Energy conservation and management

❑ Formation of 18 member ENCON core group from various deptt.

❑ Meeting of ENCON core group - once in a month

❑ Involvement of employees during Energy audit & project implementation

❑ BEE certified two Energy Auditors

❑ Circulation of Monthly Energy Report on Intranet

❑ Review of equipment wise energy consumption in a daily meetings

❑ Selection of EE equipments during replacement & new procurement

9. Employee Awareness & Involvement

❑ Participation in Energy Award Competition every year at State & National level

❑ Energy Conservation Training to School & College students :- 514 students

CII AWARD 2017

9. External Energy Audit

Auditors Area of audit Year McKinnon & Clarke Complete Plant Jul. 04

Ingersoll & Godrej Compressed air Dec. 03 & Jan. 05

CII Complete Plant Oct. 05

Forbes Marshall Boiler & Steam systems Jun. 05

Grundfoss Pumps & pumping systems Oct. 06

Dr. Kushare & associates Air Conditioners & Power quality Sept.08

CII Water Mar. 08

IIPM Thermography Every year

Yajana Fuel services Waste heat recovery- TADL Furnace Dec.10

Uhde India Ltd. H2 vent Feb.11

British Standard Institution EN16001- Gap assessment Jul. 10

GD Apte & Co. Utility- Energy Conservation May 13

CII GreenCo Rating System - Assessment Jun.13

HYDRONRoll Coolant System Pipeline Network Analysis and Optimization

Dec. 13

British Standard Institution ISO-50001- Certification Jan.14

Atlas Capco Air compressors Jul.15

Dr. Kushare & Associates Energy audit of transformer Oct.15

Grundfoss Pumps & pumping systems Jul.16

BSI System and energy Audit Dec.17

15-17:-

▪ 9 Projects Indentified

▪ 6 Projects Implemented

▪ 3 Not implemented due high

payback period

▪ 22 Lakhs Rs. /annum saved

Area specific Energy audits are carried out on periodic basis

CII AWARD 2017

Group Execution

Action PlanJust Do It

Testing

Performance

monitoring

Failure

analysis

Register successful project

OK

NOT OK

T

O

P

M

A

N

A

G

E

M

E

N

T

Day to day issues

Challenges at work place

I

N

P

U

T

S

New ENCON technologies External and internal audits

Best practices from group companies

Best practices in other industries

Factory suggestion scheme

DMAIC

DOE

DII- Brainstorming

Solution

Ideas from visiting other industries

Ideas from GreenCO certified companies

Separate Budget Allocation- ENCON measures

9. Management of energy conservation programs

EN

CO

N C

EL

L (

18

no

s. se

ctio

n H

ea

d)

CII AWARD 2017

❑ Energy week celebration – Dec.

❑ Environment week celebration-June

❑ Training on ENCON: 1,240 hours

❑ Kaizen Competition every year

❑ LED lamp distribution camp through Domestic

Efficient Lighting Programme (DELP): 925 nos.

❑ Display of stickers throughout the plant

❑ Factory suggestion scheme

➢ Poster display

➢ Interactive workshop

➢ Sticker pasting

➢ Documentary film show

➢ Pledge reading

➢ Tree plantation

➢ Competitions

➢ Cash prizes

9. Employee Awareness & Involvement

YearENCON

training

No. of

employeesHours

15-18 Internal 212 1,048

15-18 External 21 192

Total 233 1,240

Apr’16

CII AWARD 2018

Daily, Monthly and yearly review of energy consumption and savings

Annual Performance Report

Energy consumption & Energy conservation

Daily Energy Consumption Report

Equipment wise absolute and specific consumption of Electricity, LPG, Furnace oil,

Nitrogen, Hydrogen and water for main equipments.

Monthly consumption report

▪ Electricity- KWh

▪ LPG- Kg

▪ Furnace oil- Liters

Hydrogen gas

Nitrogen gas

Monthly specific energy

consumption report

Monthly energy conservation report

• Steam- Kg

• H2 gas- M3

• N2 gas- M3▪ Units/ MT

▪ Before and after consumption with monetary saving

9. Energy Consumption & Conservation Monitoring reports

✓ Comparison of

actual verse

expected

✓ Analysis of

variations

✓ Comparison of

before and

actual

CII AWARD 2018

10. Integrated Management System & GreenCO certification

Integrated ManagementSystem

ISO

90

01

Quality

ISO

50

00

1

OH

SAS1

80

01

ISO

14

00

1

EnergySafetyEnvironment

We have invested 1% of turnover for energy conservation projects

GreenCo certification in 2013.ISO 50001 certification in 2014.

First Steel Company to receive GreenCO Award

CII AWARD 2018

Achievements

Consistent performance – Recognition at State and National level

CII- National Level Energy Awards Year

Excellent Energy Efficient Unit 2006

Most Useful Presentation 2006

Water Efficient Unit 2006

Energy Efficient Unit 2007


Green Company- Silver rating 2013

Excellent Energy Efficient Unit 2013



Innovative project 2016


Innovative project 2017

MEDA- State Level Energy Awards

Second prize in Metal & Steel sector 2004


First prize in Metal & Steel sector 2006

Continuous Excellence in Metal & Steel sector 2007





Third prize in Metal & Steel sector 2015

CII- State Level KAIZEN Awards Year

Third Prize 2014

Appreciation Prize 2015

CII AWARD 2017

Environment Quality: Tree plantation

309 t CO2 sequestered by 12,350 tree plantation

➢ One tree takes up about 0.025 tonne

of CO2 net in a year

CII AWARD 2018

Thank you for your attention.

We know there is a lot in your minds

national award for excellence in energy management 2018 · 2018-09-13 · company profile &...

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