JSW Steels Limited PDF

JSW Steel Ltd
(A Unit of O.P. Jindal Group of Companies)
• A fastest Growing Steel plant in the country

• Achieved annual turnover of Rs.19457crores
• Won Prestigious Steel Minister’s Trophy award
for its Excellence in steel industry
• On completion of Project Falcon, JSW Steel
will become largest steel plant in single
location
1
Saving in Everything We Do Sep-2010
JSW : Process Flow

Non - coking coal Iron ore Coking coal Fluxes
Lump ore
Beneficiation Coke oven

Lump ore
Pelletization
Sintering
HMPT
Billet Caster Wire Rod / Re Bar Mill
Corex Blast furnace HSM CRM

Converter LHF, RH Slab Caster
2
1
Uniqueness
• 100% stamping in both recovery and non recovery type Coke

oven batteries
• Energy Efficient Corex hot metal making unit
• Highest No. of gas holders (6 No.s)
• Largest Corex gas holder (capacity: 1,00,000Nm3)
• Handling 4 types of Gases
• Common CV of 1850kcal/Nm3 for all units
• Captive power plant based on Waste heat generating 65MW
power
• Captive power plant based on 100% byproduct gases
• Zero consumption of Petroleum fuel for Iron making
• Hot charging of slabs more than 65% in Hot strip Mill furnace
• All 3 furnaces operating with Pulverized coal injection
• Only Steel plant to deliver CDM benefits
• Largest Blast furnace , Largest HSM in India
3
s
c
Sp Energy Consumption
l / T
7.2
7 Reduction in Sp Energy
6.98
Consp over 2008-09 is
a
6.8
6.847 3.12%
6.704
c
6.6
6.495
6.4
G
6.2 6.2
6
2006-07 2007-08 2008-09 2009-10 Ex pec ted
2010-11
Y ear
Cost Analysis
Sl No Description UOM 2008-2009 2009-2010
1 Specific Energy Rate Gcal/Tcs 6.704 6.495

2 Total Crude Steel Produced Tons 3082142 5257286
3 Gcal Cost Rs/- 1475 1353
v Savings with respect to Energy Consumption over 2008-2009 is Rs 148.68 Cr
4
2
Gap Analysis w.r.t Global Best
Gap Analysis
Sp. Energy of Similar plant

5.20Gcal/Tcs
POSO, South Korea
Sp. Energy of Similar plant

JSW Steel, Vijayanagar 6.495Gcal/Tcs
Works
Gap 1.295 Gcal/Tcs
5
Gap Analysis (Contd..)

Sl Effect in
No
Description POSCO JSW Gap Remarks
Gcal/Tcs
To reduce hot metal

94 rate JSW Steel is
1 Hot Metal rate 933 1027 0.38
Kg/TLS installing DRI
Plant
Projects are on for

BF gas
2 100% 83% 17% 0.322 implementation
Utilization
in boilers
CDQ in recovery
Project are under
3 type coke 100% Nil 100% 0.186
implementation
oven
Heat recovery
from flue gas Project are under
4 100% Nil 100% 0.123
stoves and implementation
sinter cooler
Total 1.011
Gap Gcal/Tcs
6
3
Energy Conservation Initiatives 2009-10.
• Coke ratio at Corex was lowered by 6.7%. This was achieved by

better heating regime and consistent coal availability.
• Coke rate at blast furnace was lowered by 9.3% by increasing the
PCI. This was achieved by increased availability of Blast furnace
operation.
• LCP heat rate was lowered by 5.6% and power rate was lowered by
6.8%. This has been achieved by increased availability of gases to
Calcining plant.
• LD gas recovery at BOF has improved by 1.7%. It was possible by
100% gas holder availability and installation of gas boosters.
• 5. HSM heat rate was lowered by 4.2% and power rate was lowered
by 11.9%. This was achieved by eliminating idle hours of HSM due to
non availability of gas and by ensuring more availability of gas to
reheating furnace.
• Mills have stabilized its operation due to over all increase in value
added products. Power rate of CRM has lowered by 13.25%
• Corex gas utilization has improved from 97% to 97.94% by better
gas management.
• Waste heat utilization at non-recovery type coke ovens waste heat
recovery power plant was improved and there was increase in power
generation from 72.39MWh to 106.23MWh also with increased by-
product gas utilization
• Gas based captive power generation has increased with better gas
management.
7
Energy Saving Projects

Total
Annual Inve
Annu
Electrical Annual thermal st.
al
Savings savings Mad
Savi
Sl Year of achieved e
Title of Energy Saving ngs
N Implementa
project implemented In terms
o tion
Rs of Rs Rs Rs
Units
Milli Quantity Milli Millio Millio
Million
on or on n n
Gcal/Tcs.
Third Booster to 105 Gcal
1 improve LD gas 2007-08 - - of energy 98 98 45
recovery. recovered
Annually
550 tons
2 Sand heating in BOF. 2007-08 - - of LPG is 24.8 24.8 0.12
being
saved.
Annually
Replace of LPG by 730 tons
3 Byproduct gas in 2007-08 - - of LPG is 32.9 32.9
Boiler Burners. being
saved.
30,000
BF Gas Holder for
Nm3/hr
4 improving utilization 2007-08 113 113 220
of gas
of BF Gas
utilized
8
4
Energy Saving Projects
Total
Annua
Annual Electrical Annual thermal Invest
l
Year of Savings achieved savings . Made
Sl Title of Energy Saving Saving
Implementat
No project implemented s
ion Rs In terms of Rs
Units Rs Rs
Millio Quantity or Millio
Million Million Million
n Gcal/Tcs. n
By
stabilization
Captive power generation of BF gas
5 has increased from 86.87 2008-09 6.48 176.5 pressure - 176.5 Nil
MWh to 93.35 MWh. with the
help of BF
gas holder
Waste heat utilization and
by product gas utilization
has improved at Non
recovery type coke oven
6 2008-09 13.22 360.2 - - 360.2 Nil
based captive power plant
resulting in increase of
power generation from
59.16 MWh to 72.38 MWh
Energy
By effective control of off Consumptio
blast and increased plant n has
7 availability increase in the 2008-09 - - increased 262 262 Nil
CDI rate by 18.39% over from 0.377
the last year to 0.464
Gcal/tcs.
LPG consumption has been
Energy
reduced from 12.61
Consumptio
Tons/day to 10.9 Tons/day
n has
by replacing LPG by Corex
8 2008-09 - - reduced 24.59 24.59 25
gas in BF flare stack pilot,
from 0.015
sand heating system in BOF
to 0.0125
and in BF boiler by
Gcal/Tcs.
modifying the Corex gasline
9
Energy Saving Projects Total

Annua
Annual Electrical Annual thermal Invest
l
Year of Savings achieved savings . Made
Sl Title of Energy Saving Saving Payback
Implementat
No project implemented s months
ion Rs In terms of Rs
Units Rs Rs
Millio Quantity or Millio
Million Million Million
n Gcal/Tcs. n
Energy
Corex gas utilization has Consumptio
been improved from 93% n has
0.14
9 to 94.18% by modifying 2008-09 - - reduced 1003 1003 0.4
days
the controls in flaring from 1.455
system to 1.393
Gcal/Tcs.
LD gas recovery increased
by 45.47% over the last
year. This has been Energy
achieved by taking LD gas Consumptio
holder capital repair and n has
Within 2
10 changed the delivery mesh 2008-09 - - reduced 234 234 1
days
and also additional booster from 0.190
has also been installed to to 0.132
take care of LD gas Gcal/Tcs.
transport during booster
shutdow
Energy
Consumptio
Replacement of high
n has
pressure high CV corex gas 5
11 2009 – 10 reduced 73.58 73.58 30
by low pressure low CV BF months
from 0.015
gas for Ore Drying Furnace
to 0.012
Gcal/Tcs
Interconnection of 4mTPA-
7mTPA BF gas line network 60,000Nm3/
3
12 for ensuring BF gas to 2009-10 Hr Flared 367 367 90
months
CO#3, even during shut gas is used.
down of BF#3 -7mTPA unit.
This has
enabled to
generate
Increasing BF #3 Gas
and use
13 holder pressure from 2009-10 735 735 0.25 1 day
additional
1000mmWC to 1085mmWC
125,000Nm3
/Hr Mixed
gas
10
5
Team work in Encon 2009-10
Encon Team work
Sl No Project Description FY Responsible Agencies Project status
Interconnection of 4mT-7mTPA BF gas line VP(EMD), Manager

Project has
interconnection for ensuring BF gas for gas (Coke oven), Manager
1 2009-10 been
mixing station at coke oven#3 even with (EMD), Asst. Managers
completed
BF#3 under down condition and technicians
VP(EMD),Sr.Manager
Replacing HP and high CV corex gas by LP Project has
(EMD),Manager(EMD),
2 and low CV BF gas for ore drying furnace of 2009-10 been
Asst.Managers(EMD),
pellet plant. completed
Technicians
VP(EMD),Sr.Manager
Utilizing mixed gas in corex gas network by Project has
(EMD),Manager(EMD),
3 regulating Corex gas pressure in case of 2009-10 been
Asst.Managers(EMD),
one corex gas unit is under shutdown. completed
Technicians
Increasing the BF#3 Gas holder pressure VP(EMD),Sr.Manager

Project has
from 1000mmWC to 1085mmWC for (EMD),Manager(EMD),
4 2009-10 been
ensuring 100% operation of Gas mixing Asst.Managers(EMD),
completed
station. Technicians
11
Solid Waste Management 2009 - 10

Solid waste 2009-10
Quantity
Sl. Type of Generation Equivalent of
Waste used at reused /
No material , Tons Energy
recycled, t
This is 31% of total

Coal & coke Power plant, BFs,
1 1558926 1585801 energy for making
fines Coke ovens & sold
crude steel
Cement making, This is 80% of total

Iron making
2 ground granulated 1996666 1925638 energy for making
slag
BF slag cement
This is 25% of
Steel BOF as coolant,
3 1372837 254409 energy for making
making slag IM, PP & SP as flux
sinter
This is 2% of total
4 sludge Pellet plant 199030 103462 energy for making
pellet
5 dust Pellet plant & SP 129744 21212 -
6 Mill scale Base mix yard 58698 58698 Replacing iron ore
12
6
Specific Water Consumption
Specific water consumption details (m3/Tcs)
Year Consumption
2007-08 3.13
2008-09 2.93
2009-10 2.18
This has been achieved due to the following:
1.Waste water utilization at ore Beneficiation plant#2
2.Waste water also utilized for ore washing at BF#3
13
Carbon Emission Reduction initiatives
Sales
of
Percentag
Carbon 2008-09 2009-10 Variance
e
credits
Rs. 49 crores 60 crores 11 crores 23%
This pertains to carbon credit earned against following projects:

1.By-product gas uses for power generation at captive power
plant#1
2.Usage of Waste heat of non recovery coke plant for power

generation at captive power plant#2
14
7
Future CDM Projects for Green Environment
Total
Total CO2
Sl annual Investment
Projects Reduction
No Saving
Tons of Payback
Rs. Rs.
CO2/Yr months
Waste heat from B F

1 2010 17975 78.8 200 31
Stoves
Installation of Process
boiler for utilizing
2 2011 290473 436.26 60 1.5
60,000Nm3/Hr of BF
gas
Utilization of BF Gas i.e.

100000 Nm3/hr for
3 2011 484122 727.08 100 1.65
generating steam for
power generation
Part of
4 TRT for BF 4 2011 149796 630 total 18
package
CDQ for 1.2 mTPA Non

5 2011 89878 378 750 24
Recovery Coke Ovens
15
Renewable Energy at JSW
• Traffic signals and Street Lighting at steel plant and

Townships has been provided with Solar Energy.
• All the Guest houses have been provided with solar hot
water facility.
• Jatropa cultivation has been initiated at Vidyanagar

township and will be extended to around 75acres.
• The total energy generated is about 390000 units and a

saving of Rs. 1033500. by solar photo voltaic Cells.
16
8
Environment projects-2009-10
• 3 new de-dusting systems at RMHS#2 (crusher building,

screening building & proportioning building) to control the
fugitive emissions.
• Tyre washing facility near beneficiation plant #1 to arrest the

carry over of dust from the truck tyres on to the road.
• Installation of pneumatic conveying system at BF#1 de-

dusting system. This has resulted in reducing the downtime of
the de-dusting system due to the problems encountered at
the dust conveying arrangement.
• 5 de-dusting systems of Coke ovens – Installed at the coal

crusher house, coke screening & coke cutter house.
• 10 no. of stack monitors to monitor the dust level on a

continuous basis.
• 3000 m3/hr. Compressor to cater to the new de-dusting

systems & dry fog dust suppression systems
17
Environment projects-2009-10
• AAQ at 3 stations to monitor PM 2.5, PM 10, TSP, SO2,

Nox & CO on a continuous basis
• SGP at SMS1 to granulate the slag.
• DSS at RMHS junction houses & yards to control the

fugitive emissions from yards & junction houses.
• Gas cooling at SP1 to control the temperature & hence
reduce the damage to the electrodes.
• Pneumatic conveying at PP to utilize the bag filter dusts

from various plant units.
18
9
ISO - NCRs for 2009-10( OCT09- Mar10)
• To collect the dust generated during hot metal handling.

Present Level: SPM 3763 microg/m3
Target : SPM 1500microg/m3.
Objective :To collect the dust generated during blowing.
• Present level: SPM 4063 microg/m3 during blowing

Target: SPM 1500 microg/m3
1. No action plan to implement the above evidenced.
2. SPM level not monitored since January 2009 to till date.
3. Since it is significant environment aspect auditee needs
to take measures to control and bring it to the target level /
norms as required by the applicable Environment act (EP
Act 1986 amended in 1999).
19
ISO Corrective action 2009-10
• Management to take the decision reg. Performance of

Secondary De-dusting Systems for Mixer and Converter 2.
• EMD being central authority for monitoring dust levels
help from EMD required to monitor the dust levels in these
areas.
• Risk assessment of SP1- JB1C2 conveyor being reviewed

and revised with immediate effect.
• Testing has been done but test report is awaited. As soon

as the test certificate is recd. same will be submitted for
inspection
20
10
ISO Preventive action 2009-10
• As per the MOM of MRM No.36 dt.23/07/09, a circular has

been issued to ensure usage of PPE’S in the work zone till
the desired levels are achieved. The copy of the circular is
attached. 2. EMD has agreed to continue monitoring the
dust levels in these areas as it was done earlier.
• Henceforth, corrective and preventive action shall be

taken after any incident after reviewing the risk
assessment of the concerned activity.
• Test Certificates will be avl. in time. Follow up will be

initiated with Safety Dept. so that test certificates are
recd. in time.
21
Energy Based Innovative projects 2009-10
• Installation and commissioning of BF gas network

interconnection of 4mTPA and 7mTPA operating at varied
operating pressure with control system:
Net Saving: Rs 36.792Crores
• Replacement of high pressure and high CV corex gas by low

pressure and low CV BF gas for ore drying at Pellet plant:
Net saving: Rs 91.98crores
• Up gradation of BF gas holder pressure from 1000mmWC to

1075mmWC
Net saving: Rs 168.192crores
• Utilizing 970mmWC mixed gas in 1000mmWC corex gas

network during one Corex gas unit under Shutdown
condition by controlling pressure in Corex gas network
Net saving: Rs 50crores
22
11
Up gradation of BF gas holder pressure from
1000mmWC to 1075mmWC (Innovative project)
• BF#3 gas holder was designed for a pressure of 1000mmWC
• Before commissioning of gas holder, BF gas network was operated
with a pressure of 1150mmWC.
• It was experienced that, there was fluctuation of BF gas pressure in
the upstream side of gas mixing station near Oxygen plant.
• Outlet of this mixing station was against Corex gas network
pressure of 950 to 980mmWC.
• Due to fluctuation of upstream pressure 970 to 1000mmWC at Gas
mixing station, mixed gas generation i.e BFG+COG was varying in
between 30000Nm3/Hr to 40000Nm3/Hr.
• With 1000mmWC pressure of gasholder, there would be drop in
pressure up to 10mmWC and it would not have been possible to
generate mixed gas.
• Therefore, a proposal was made that gasholder pressure to be
1200mmWC.
• Accordingly a static load on piston was calculated and was found
that, column foundation and structural can’t take that much of load.
• Further, it was found that, pressure of 1075mmWC will be suitable
as around 200Tons of weight on gas holder piston will be safe with
existing foundation and columns.
23
Up gradation of BF gas holder pressure from

1000mmWC to 1075mmWC (Contd..)
• But it was found that, there is not much area on top of the
piston to accommodate concrete load of 200Tons.
• Therefore a decision was taken to use pig iron available at
plant site. Hence pig iron were anchored by concrete.
• The pressure achieved was 1075mmWC.
• This has enabled us to generate mix gas up to 160000Nm3/Hr.
Otherwise the gas was being flared.
• So there is gain of 125000Nm3/Hr of mixed gas.
• This has helped us also in generating mixed gas for largest
HSM reheating furnaces.
• Overall mixed gas generation was possible up to
165000Nm3/Hr
• Cost of mixed gas Rs. 1.22/ Nm3
• Cost of modification Rs. 25Lakhs
• Benefit works out to be 168crores/Anum
This work is one of its kind in any steel plant. This has
made the gas network viable and for generating desired
quantity of mixed gas for stable operation of plant.
24
12
BF-3 Gasholder (Innovative project)
Gasholder Dome
Designed Pressure -1000 mmWC

Pressure Increased by Adding Pig Iron -1075 mmWC
Pig Iron added to
Piston increase the weight
Dome of Piston
Concrete Blocks
Concrete
Rubber Seal
Shell
Piston Rest
Blocks
25
Energy Conservation projects 2010-2011

A
Effect on Sp.Energy
Sl No Project Description Investment
in Gcal/Tcs
Installation of 2 No.s of BF
1 gas fired boilers for Rs.600 Million 0.064
process Steam
Interconnection O2 and N2
header of all Oxygen
2 plant for flexibility of Rs 50 Million 0.05
operation so as to
operate all units
Replacement of HP Corex
gas by BF gas for 2nd
3 Rs. 8 Million 0.0128
Ore drying furnace of
pellet plant
4 Up gradation of EMC SCADA Rs 8 Million 0.02
BF gas to power plant for

5 Rs 8 Million 0.1
power generation
Total 0.2468
26
13
Energy Conservation measures 2010-2011
B
Effect on
Sl
Project Description Sp.Energy in
No
Gcal/Tcs
Increasing BF Coal rate from
1
66. 23 to 100kg/THM
0.0682
Reduction of BF coke rate from
518 to 480kg/THM
Increasing the utilization of
2 Corex gas from 97.94 to 0.012
98.94%
Increasing TRT power generation
3 0.02
from 3MWh to 8MWh
Total 0.1002
Total Effect on Sp.Energy Consumption = A+B

= 0.347Gcal/Tcs
27
Best Practices Observed On Energy Front
• Preparing Energy budget with regard to byproduct gas

yield, Gas CV, Heat rate, Power rate, Utility utilization in
shops. Budget as per experience and Energy improvement
projects
• Energy Management through SCADA.
• Delay strategy followed by shops during short and long

shutdowns.
• Low cost, No cost solutions for energy related problems.
• Planning and implementation of Energy conservation

projects under Capex.
• Continuous work for Energy security.
28
14
Energy Security Efforts at JSW
• Optimizing the PCI (Pulverized Coal Injection) to reduce

costly coke in all Blast furnaces
• Utilizing more than 15% non coking coal in coke ovens
• Corex gas utilization is > 98.4%
• Efforts are on for BF gas utilization > 95% by 2012
• Has Installed TRT @ BF#3 i.e. for High Top pressure blast
furnace
• About to install CDQ for recovery type coke ovens and

produce 50MWh power generation
• JSW Steel is set to get Natural gas, another important

measure for Energy Security
29
Energy Report
Energy Management Department For June 28, 2010
Daily Plant Energy MIS
Production
Shops
On Date Till date Parameter Unit Target On Date Till date
CO 1&2 Gross Coke % 74 70.8 71.2
No of pushing Nos 112 108 108
Coke oven 1&2 2409 67348 Waste heat power Mwh 55.6 53.5
64
Power Rate Kwh/tp 12 16.42 16.51
CO3 Gross Coke % 74 72.4 72.5
Specific heat Gcal/Tdc 0.65 0.61 0.61
CO 3 gas yield Nm3/tdc 310 332 315
Coke oven 3 4265 116572 Tar yield % of tdc 2.85 2.91
3.2
No of pushings Nos 224 221 216.5
Power Rate Kwh/tp 55 57 57
Gaseous Heat rate Gcal/T 0.007 0.007 0.007
Sinter Plant 1 6469 184574 Coke Breeze Heat Gcal/T 0.388 0.402
Power Rate KWh/T 40 42 39
Gaseous Heat rate Gcal/T 0.007 0.006 0.006
Sinter Plant 2 7838 207757 Coke Breeze Heat Gcal/T 0.194 0.150
Power Rate Kwh/T 40 38 39
Gaseous Fuel rate Gcal/T 0.12 0.13 0.131
Pellet Plant 10600 293540 Power Rate KWh/T 65 67
70
30
15
Energy Report
Production
Shops
Coal Rate Crx 1 Kg/Thm 815 900 867
Coke Rate Crx 1 Kg/Thm 170 185 199
Corex 1 2207 55246 Oxygen Rate Crx 1 Nm3/Thm 560 615 744
Nitrogen Rate Crx-1 Nm3/Thm 125 144 288
Gas yield Crx 1 Nm3/Thm 1680 1,638 1,817
Coal Rate Crx 2 Kg/Thm 815 963 899
Coke Rate Crx 2 Kg/Thm 170 159 191
Oxygen Rate Crx 2 Nm3/Thm 560 630 615
Corex 2 2003 56535 Nitrogen Rate Crx 2 Nm3/Thm 110 122 118
Gas yield Crx 2 Nm3/Thm 1680 1,812 1,798
Corex gas C V Kcal/Nm3 1855 1,870 1,898
Power Rate KWh/Thm 85 109 113
Coke Rate BF 1 Kg/Thm 520 452 466
CDI Rate BF 1 Kg/Thm 80 100 90
Gas yield BF 1 Nm3/Thm 1750 1,609 1,675
Blast Furnace 1 2841 74352 Oxygen Rate BF 1 Nm3/Thm 48 46
70/100
Nitrogen Rate BF 1 Nm3/Thm 50 48 46
Heat rate (stoves) Gcal/Thm 0.63 0.45 0.44
Blast Furnace 2 3609 86029 Oxygen Rate BF 2 Nm3/Thm 55 55 45
Nitrogen Rate BF 2 Nm3/Thm 50 65 83
Power Rate KWh/Thm 50 48.8 53.55
31
Energy Report
Production
Shops
Oxygen Rate BF 3 Nm3/Thm 50 90 84.87
Blast Furnace 3 8273 192424 BF 3 Nitrogen Rate Nm3/Thm 36 58
50
B F 3 Power rate KWh/Thm 160 147 160
B F gas C V Kcal/Nm3 750 750 750
Heat rate Gcal/Ton 0.75 0.75 0.79
LCP 1875 46786 Power rate KWh/Ton 37 35
34
Oxygen rate Nm3/Tls 54 57 59
Nitrogen rate Nm3/Tls 28 50 46
SMS 1 10238 259675 Power Rate KWh/Tls 45 42 43
Hot Metal rate Ton /Ton 1.027 0.996 1.024
LD Gas Recovery Nm3/Tls 100 113 107
Argon Rate Nm3/TSla 2.00 1.20 1.39
CCP 1 10153 256235 Power Rate KWh/TSla 18 19
18
Oxygen rate Nm3/Tls 54 59 59
Nitrogen rate Nm3/Tls 28 45 39
SMS 2 7140 177882 Power Rate KWh/Tls 45 70 69
Hot Metal rate Ton /Ton 1.027 1.216 1.235
LD Gas Recovery Nm3/Tls 100 0 0.00
Argon Rate Nm3/TSla 2.00 1.82 2.15
CCP 2 7049 174687 Power Rate KWh/TSla 30.6 30.0
18
Heat rate Gcal/Tp 0.27 0.279 0.368
HSM-1 9903 227290 Power Rate KWh/Tp 90 80 88
32
16
Energy Report
Production
Shops
HSM-2 728 79444 Power Rate KWh/Tp 90 419 190
WRM 1702 29025 Power Rate KWh/Tp 160 156 212
BRM 2094 29892 Power Rate KWh/Tp 110 109 175
CRM CPL Heat rate Gcal/Tp 0.298 0.90 0.165
CRM CCM 380 66113 Power Rate KWh/Tp 95 613 129
BF gas consumption Nm3/hr 165000 103,908 94,669
CPP-1 104 2796 Corex Gas Cons Nm3/Hr 85000 98,513 96,305
Total Generation MWh 100 104 99
Corex Gas Cons Nm3/Hr 25000 19,410 21,454
CPP-2 111 2976 BF gas consumption Nm3/Hr 175000 136,333 120,111
Total Generation MWh 120 111 107
Plant load MWh 360 291 285
Electricity Specific power KWH/Tcs 406 447
560
Iron 4 mTPA BF # 3 SMS #1 SMS # 2 HSM-1 CRM Total/day
3.90 0.05 3.80 3.90 0.52 0.39
LPG
WRM & Others JPOCL BOC # 1 & 2 14.87
0.20 1.91 0.20
Losses (%) Corex gas 1.65 CO Gas 0.11 BF 1 & 16.62 BF 3 Gas 15.56
Specific Energy Consumption 6.67 (with BP norm) On date 6.34 Till Date 6.50
Remarks: 1)Good Hot metal rate in SMS -1 i.e 0.996 Thm/Tls. 2) Good Coke rate in Blast Furnace -1,
2 & 3. 3) Good CDI rate of Blast Furnace -1 i.e 100 Kg/Thm.
33
ENERGY – A Major Thrust at JSW
JSW Steel Since inception has taken care of Energy Efficient

technologies
JSW Steel Cares for Energy
• Daily Energy Review during ED(O) & HOD’s Meeting
• Energy is reviewed during weekly cost meeting
• SEC is the Key Result Area for Senior and Top Management
• CEO Reviews Energy during weekly production performance

meeting
• CEO Reviews Energy during monthly production meeting
• MD Reviews performance of Energy conservation activities,

future plans and encourages team for achieving set goals.
34
17
35
18

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JSW Steel Ltd

(A Unit of O.P. Jindal Group of Companies)

• A fastest Growing Steel plant in the country

JSW : Process Flow

Beneficiation Coke oven

Billet Caster Wire Rod / Re Bar Mill

Corex Blast furnace HSM CRM

• 100% stamping in both recovery and non recovery type Coke

1 Specific Energy Rate Gcal/Tcs 6.704 6.495

Sp. Energy of Similar plant

Sp. Energy of Similar plant

Gap 1.295 Gcal/Tcs

Gap Analysis (Contd..)

To reduce hot metal

Projects are on for

• Coke ratio at Corex was lowered by 6.7%. This was achieved by

Energy Saving Projects

Energy Saving Projects Total

Sl No Project Description FY Responsible Agencies Project status

Interconnection of 4mT-7mTPA BF gas line VP(EMD), Manager

Increasing the BF#3 Gas holder pressure VP(EMD),Sr.Manager

Solid Waste Management 2009 - 10

This is 31% of total

Cement making, This is 80% of total

5 dust Pellet plant & SP 129744 21212 -

Specific water consumption details (m3/Tcs)

This has been achieved due to the following:

1.Waste water utilization at ore Beneficiation plant#2

2.Waste water also utilized for ore washing at BF#3

Carbon Emission Reduction initiatives

Rs. 49 crores 60 crores 11 crores 23%

This pertains to carbon credit earned against following projects:

2.Usage of Waste heat of non recovery coke plant for power

Waste heat from B F

Utilization of BF Gas i.e.

CDQ for 1.2 mTPA Non

Renewable Energy at JSW

• Traffic signals and Street Lighting at steel plant and

• Jatropa cultivation has been initiated at Vidyanagar

• The total energy generated is about 390000 units and a

• 3 new de-dusting systems at RMHS#2 (crusher building,

• Tyre washing facility near beneficiation plant #1 to arrest the

• Installation of pneumatic conveying system at BF#1 de-

• 5 de-dusting systems of Coke ovens – Installed at the coal

• 10 no. of stack monitors to monitor the dust level on a

• 3000 m3/hr. Compressor to cater to the new de-dusting

• AAQ at 3 stations to monitor PM 2.5, PM 10, TSP, SO2,

• SGP at SMS1 to granulate the slag.

• DSS at RMHS junction houses & yards to control the

• Pneumatic conveying at PP to utilize the bag filter dusts

• To collect the dust generated during hot metal handling.

• Present level: SPM 4063 microg/m3 during blowing

ISO Corrective action 2009-10

• Management to take the decision reg. Performance of

• Risk assessment of SP1- JB1C2 conveyor being reviewed

• Testing has been done but test report is awaited. As soon

• As per the MOM of MRM No.36 dt.23/07/09, a circular has

• Henceforth, corrective and preventive action shall be

• Test Certificates will be avl. in time. Follow up will be

Energy Based Innovative projects 2009-10

• Installation and commissioning of BF gas network

• Replacement of high pressure and high CV corex gas by low

• Up gradation of BF gas holder pressure from 1000mmWC to