Energy Management Practices at Tata Sponge

Bijay Kumar Agrawal

Head(Electrical), CEA(EA-11295)
S.K Sahoo, Manager(Operation)
S.B.Mohanty, Dy. Manager (Mechanical)
Tata Sponge Fact File
DRI Capacity : 390,000 MT/Yr
Power Generation: 26 MW
Consistently earning YoY profits for
the past 20 years & paying dividends
First DRI company to earn CDM
benefits
First DRI company to be certified in
ISO-9001, ISO 14001 & OHSAS 18001
1st DRI Company to receive TPM
Certification in the World.
Energy Conservation award from CII
(ER) for 2013-14
Frost & Sullivan Green
Manufacturing Award (Gold
Category)
13 on Quality {4 from CII (ER)} 15
awards on Environmental care
16 safety awards, 4 appreciation on
CG, 2 on HR, 1 on value creation,….
Manufacturing Process

5 1
1

3 1 2
2
3

Thermal Energy Use/Loss

Electrical Energy

WHR/Power Gen/Export
4
4
 The “Q” Approach
WITH WHAT (Philosophies & Tools) WITH WHOM (Competence/Support)
•Rotary Kiln equipment
• Support from Promoter
•Power plant equipment.
• 3 level structure
• 220KV System equipment
• Competent & skilled Workforce
•Right Mix of Coal Procurement
• Professional Consultants
•TPM Methodology/ Statistical Tools

INPUTS OUTPUTS

• BEE/PAT Targets in ToE • Reduction in Sp. Energy consumption

Energy
• Energy Policy Management • Compliance to PAT target
• Energy Audit recommendations • Reduction in tCO2 emission per ton of
• Best Practices & Benchmarks DRI

HOW (Procedures & Methods) WHAT RESULTS

• Energy Awareness Campaign Reduction in C/Fe Ratio Increase in Power Export
• Approach to Energy Efficiency Improvement to Grid
Efficiency

Activities

Effective
• Implementation of energy audit Reduction in Coal per
Reduction in SEC(Elec),
recommendations ton of DRI
• IT Based Systems (KPI tracking, ERP) Sp. Steam Consumption Reduction in SEC (Thermal)
• Automations to check energy wastage
 PAT SEC reduction target by BEE

Baseline SEC
SEC

Reduction in SEC
Target SEC

Y1 Y2 Y3

• Baseline SEC : 0.581 ToE /MT of SI

• Target SEC : 0.551ToE /MT of SI
• Baseline production : 359333MT
• PAT cycle :2012-2015
Energy Policy
As an energy intense manufacturer of Sponge Iron through Coal based DRI
Kilns & Power Generation through WHRB strives to reduce its energy
consumption and costs and promote the long-term environmental and
economic sustainability of its operations.
We are committed to:
 Reduce energy use per ton of production by 7.5 % in 5 years in our
operations.
 Ensure continual improvement in our energy performance.

 Deploy information and resources to achieve our objectives and targets.

 Uphold legal and other requirements regarding energy.

 Consider energy performance improvements in design and modification

of our facilities, equipment, systems and processes.
 Effectively procure and utilize energy-efficient products and services.

Managing Director
Tata Sponge
3 Levels Energy Team Structure

Managing Director Production

Chief Operating Officer Power Plant

A

Energy Auditor Maintenance & Utilities

Core Group1 Core Group2 Core Group3 Core Group 4

Working Working Working Working

Group Group Group Group
Process for Energy Awareness Campaign
•Support & Resources
•Current level
Planning •Target Audience
•Message & communication Channel

•Assign role & responsibilities

•Gather & Prepare promotional materials
Implementation •Launch programme

•Compare present energy consumption level with

target level
•Measure the success of the programme
•Feedback
Checking & Review
•Report to staff & Management

•Energy awareness section in start up kit to new

employees
Maintaining •Maintaining the momentum
•Campaign tool: suggestion scheme, competition,
reward & recognition,
Awareness Training on ISO 50001(EnMS)
BSI Certified Lead Auditors for
ISO 50001 EnMS: 2 nos
3 days in-house training on awareness on
ISO 50001 conducted

25 persons from various functional areas

participated

Effectiveness of the training was

evaluated through a test
Various forms & formats were developed
as a part of implementation of the EnMS

Implementation plan was formulated & it

is in progress.
Approach to Energy Efficiency Improvement Activities
Mapping of Energy
Consumptions(Electrical & Thermal)
Identifying Thermal & Electrical
Energy Losses
Formulation & Prioritization of
Action plans for both Thermal &
Electrical ENCON projects
• External Energy Audits
• PAT Targets/Obligation
• ISO 50001 methodology
• Best Practices/Benchmark
• Climate Change Policy
• New Technologies
• Training

Form C F Team for Implementation of

the ENCON Projects
R&R
Data Collection
No Training
Target Yes
Analysis of Energy losses Upload in
achieved?
Develop Kaizen Ideas for Knowledge Portal
ENCON
Daily review through KPI Tracker, ERP/SAP,
Prioritization of options Check & Fortnightly review by COO(SB)
& kaizen Implementation Review Monthly review by MD
Encon Projects(illustrative) implemented-Electrical Energy

• Replacement of Impeller of Kiln #2 ID fan motor (3.3KV,260KW motor)

• Replacement of under loaded LT motors with correct size motors of DE system
of Kiln#1 & Kiln#3
• Auto Operation of Cooling Tower fan motors (2X22KW) of Kiln#3 with Sponge
Temperature.
• VFDs for pump motors running in throttled condition( 2X90 KW Hot Well Pump
Motor & Cold well pump motor of Kiln#3)
• Different VFD panels for odd & even set of SAB motors of Kiln#1
• Delta to star connection for cooling tower motors (2X15KW)of Kiln #1
• Use of day light in mechanical workshop & conveyor galleries by replacing
some of the GC sheets with transparent sheets.

• Improvement of power factors at MCC level and maintain at >0.95

• Lighting control through timers.

Encon Projects(illustrative) implemented-Thermal Energy

• Use of 100% South Africa Coal (both feed & injection) and use of 0-3
mm fines in feed side without rejecting any fines. Changing the coal ratio
from 60:40 to 45:55 (feed: injection) (Period 15th Jun'2014 to Till date)
• Kiln Shell Painting with heat resistant Paint to reduce the radiation
temperature by 20 degree cent.
• Covering the coal heap from exposure to moisture at Paradeep Port to
reduce moisture absorption.
• Covering the coal heap at TSIL yard to reduce wind loss.(0.19% in
2014-15 from 0.31% in 2013-14)
• Covering coal in transit (wagon & truck) to reduce loss. (Transit loss
reduced from 1.08% in 2013-14 to 0..55% in 2014-15 )
• Use of "Thermact" as additives in feed coals for proper combustion of
coal inside the Kiln-2(efficiency improvement)
• Top Management’s involvement in enhancing productivity. Operative plants at more than
design value( daily production is ranging between 1250 to 1350 MT /day against design
capacity of 1250MT/day, 7.8 MW from 7.5MW PP and 19.2MW from 18.5MW PP)
 After application of Heat Shield
Paint on the kiln shell

Arrangement showing feeding of

Thermact (catalyst) inside the Kiln
Covering of Coal at Yard

Brining Coal in covered wagon

Covering of Coal
at Paradip Port
Snap Shot of the KPI tracking system
Lead/KPI/Efficiency Measures

Good
Carbon to Iron(C/Fe) Ratio
0.470 0.465
0.460
0.460 0.454
0.451 0.447
0.450

0.440 0.438
Ratio

0.430 0.428
0.420
0.420

0.410

0.400

0.390
2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2015-16
(Upto (Target)
Dec'15)
Lead/KPI/Efficiency Measures, Contd..

Good
Specific Coal consumption(Ground) per ton of DRI
1.4 1.242 1.26 1.281
1.208
MT of Coal /MT of DRI

1.2 1.112
1 0.892 0.888 0.85
0.8

0.6

0.4

0.2

0
2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2015-16
(Upto (Target)
Dec'15)
Lead/KPI/Efficiency Measures, Contd..

Good
Specific Coal consumption(Fed to Kiln) per ton of DRI
1.4
MT of Coal /MT of DRI

1.2 1.091 1.052

1.03
0.983 0.974
1
0.863 0.843 0.85
0.8

0.6

0.4

0.2

0
2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2015-16
(Upto (Target)
Dec'15)
Lead/KPI/Efficiency Measures, Contd..

Good
Specific Steam consumption (7.5MW Power Plant)
4.4
4.38

4.35
Steam in Ton/MW

4.30
4.3

4.25
4.25

4.20 4.20
4.2

4.15

4.1
2012-13 2013-14 2014-15 2015-16 (Upto 2015-16 (Target)
Dec'15)
Lead/KPI/Efficiency Measures, Contd..

Good
Specific Steam consumption (18.5MW Power Plant)
4.4 4.37

4.3
Steam in Ton/MW

4.2
4.14
4.11 4.11
4.1
4.05

3.9

3.8
2012-13 2013-14 2014-15 2015-16 (Upto 2015-16 (Target)
Dec'15)
Lag/KPM/Effective Measures, Contd…
Good
Specific Thermal Energy Fed to kiln(Kcal/Kg of DRI)
0.580
0.575
0.570
0.570 0.567
Kcal/Kg of DRI

0.560

0.550

0.540 0.540
0.540

0.530

0.520
2012-13 2013-14 2014-15 2015-16 (Upto 2015-16 (Traget)
Dec'15)
Lag/KPM/Effective Measures, Contd…
Good

Specific Electrical Energy Consumption

105

100.54
100
kWh/MT of DRI

95 94
92.42

90
86
85
85

80

75
2012-13 2013-14 2014-15 2015-16 2015-16
(Upto Dec'15) (Target)
Lag/KPM/Effective Measures, Contd…
Good
Power Export
160
140.91
140 131
123.78 121.42
120
Million Units

100
81.08
80

60

40

20

0
2012-13 2013-14 2014-15 2015-16 (Upto 2015-16 (Target)
Dec'15)
Specific Energy Consumption (MJ/MT) including losses

Good
30.4
30
28.8

28
MJ/MT of SI

26
24.9

24

22
22

20
2012-13 2013-14 2014-15 2015-16
(Target)
Status of Specific Energy Consumption (SEC) achieved as per M&V
report under Perform Achieve Trade(PAT) methodology

We are the only Designated Consumer under Iron & Steel sector in Odisha state

who has submitted all the requirements of PAT compliance within deadline

of 30th Jun’15 .

Total DCs under Iron & Steel sector:- India:67nos ; Orissa:15 nos

Notified Baseline SEC: 0.581ToE/MT

Notified target SEC: 0.551 ToE/MT.

Reduction target: 0.03ToE/MT

Over Achieved SEC reduction target.

We have claimed quite a good nos of Energy Saving Certificates for our effort.
Environmental Concerns
CO2 emission
Good
2.15

2.1

2.05
tCO2/t of DRI

2
1.97
1.95
1.91
1.9
1.87
1.85 1.85
1.85 1.83
1.8
1.8

1.75
2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16
(Target)
ENCON Projects- Ongoing

The following pilot projects have been taken up with the help of external
agencies to improve thermal energy efficiency of the plant.
1) Working further with supplier to improve life of the paint to reduce the
radiation loss.
2) Exploring technological options (Oxygen Enrichment) to improve utilization
of Thermal Energy.
3) Exploring technological options for recovery of heat which is being lost
a)from exhaust gas (which is at 170-180°C )
b)Indirect cooling of product from 1050°C to 100°C
Thank You