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First Workshop on Best Practices in Energy Efficiency in Sponge Iron & Steel Sector

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Date/Time
Date(s) - 04/03/2016
9:00 am - 5:30 pm

Location
Hotel Babylon Inn

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4 March, 2016, Raipur, Chhattisgarh : The 1st Iron & Steel sector workshop for promoting exchange of “Best practices in Energy Efficiency in Iron & Steel sector” under Knowledge Exchange Platform (KEP) initiative was hosted by Godawari Power & Ispat Limited, on 4th March, 2016 at Raipur Chhattisgarh. KEP is a joint initiative of Bureau of Energy Efficiency (BEE) and Institute for Industrial Productivity (IIP) for promoting energy efficiency through best practice transfer in industries covered under the Perform Achieve and Trade (PAT) scheme. KEP provides the institutional framework to catalyze the transfer of best practices within and across the industry sectors covered under PAT Scheme.

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Shri Vivek Agrawal, Chief Operating Officer, Godawari Power & Ispat Limited delivering his inaugural address.

Welcome address was delivered by Shri K K Chakarvarti, Expert Consultant Bureau of Energy Effieicny. He made a brief presentation on the rationale behind KEP, objectives and vision and the milestones achieved so far with the continued support of industries. He also highlighted the fact that although KEP although being in infancy stage, has undertaken commendable work since its inception in February 2015. Six Best practices workshops for Aluminium, Cement, Paper and Pulp, Thermal Power, Textile sector and Fertiliser sector have been successfully organized, attended by more than 1100 industry professionals. He also highlighted that cross sectoral knowledge transfer has also been high on KEP’s agenda and this was initiated by sharing of best practices in thermal power sector through a workshop and exposure visit for the benefit of other industry sectors having large captive power plants. 60 plants from all the PAT sectors have agreed to participate in Friendly Energy Efficiency Exchange Visits. Policy Roundtables on ESCerts Trading, Financing and Spent Pot Liners (SPL), a hazardous waste, generated from the aluminium sector and its gainful utilization in the cement industry, have been organized.

He also informed the participants KEP has launched an interactive website (www.knowledgeplatform.in) that facilitates knowledge transfer and discussion between stakeholder groups related to different PAT sectors and requested participants to give their feedback on different features to ensure that it met industry’s expectations and needs. While concluding his welcome address, he hoped that with these initiatives, KEP will be able to deliver significant energy efficiency benefits for the industrial sector and help sustain continuous improvement by promoting cost effective efficiency measures.

Special addresses were delivered by Shri Shailendra Kumar Shukla, Chief Operating Officer, Chhattisgarh State Renewable Development Agency (CREDA), Shri Abhishek Agrawal, Executive Director, Godawari Power and Ispat Limited and Vote of thanks by Shri Lakshman Prasad, Advisor (Mineral Resources and Environment), Godawari Power and Ispat Limited.

The inaugural event was followed by four technical sessions and a panel discussion. The first technical session was Chaired by Shri Vivek Agrawal, Chief Operating Officer, Godawari Power and Ispat Limited. The discussion in the session focused on Energy Conservation Act 2001, PAT Scheme, Trading mechanism proposed for Energy Saving Certificates (ESCerts) and Best Practices on energy efficiency. BEE made a presentation on the Energy Conservation Act and PAT Scheme wherein the participants were informed about the current status as well as next steps proposed with regard to PAT Scheme and M&V. The presentation also covered the methodology to be adopted for second PAT cycle and the new plants and sectors proposed to be added in second cycle of PAT.

Besides PAT, the session also focused on sharing of experience of the industry on implementation of innovative best practices. The industries that shared their experience included Climate Connect Limited, Godawari Power and Ispat Limited and Jindal Steel and Power Limited, Raigarh.

Sharing and discussing their innovative best practices, the presentation by Climate Connect Limited shared the international experience which could also be used to forecast the price for PAT and other Cap-and-Trade Markets. The presentation by Godawari Power & Ispat Limited focused on benefits achieved by modifications in fuel feeding systems, old screw conveying systems, modifications in FAD systems, and innovative strategies adopted in sponge iron making. The presentation by Jindal Steel and Power Limited, Raigarh highlighted the benefits achieved by modifications in steam traps & steam systems, blast furnace pressure recovery turbine and efficient lighting systems.

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Shri Vivek Agrawal with the panelists of first technical session

The second technical session was focused on sharing of experience of the industry on implementation of innovative best practices, was Chaired by Shri K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency. The industries that shared their experience included M/s. BMM Ispat Limited, by JSW Steel, Dolvi works, Usha Martin Limited (Usha Alloys & Steels Division) and technology presentation by CQM-RAJ India. The presentation by M/s. BMM Ispat Limited highlighted the benefits achieved by introducing pre-heating technology, bag-filter dust injection system into ABC and modifications in operation of ID fan. The presentation by JSW Steel, Dolvi works highlighted the benefits achieved by using coke oven in sponge iron plant which led to an annual savings of Rs. 98 crores. The presentation by Usha Martin Limited (Usha Alloys & Steels Division) highlighted the benefits achieved in electrical arc furnace by introducing innovation which led to monetary saving of Rs. 746/MT. The session also had a technology presentation on automatic tube cleaning system for shell and tube type heat exchangers for prevention of scaling by CQM-RAJ India.

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Shri K K Chakarvarti with the panelists of the second technical session

The third technical session was focused on sharing of experience of the industry on implementation of innovative best practices, was Chaired by Shri Sanjeev Jain, Chief Engineer, Chhattisgarh State Renewable Development Agency (CREDA). The industries that shared their experience included SMC POWER Generation Limited, Nalwa Steel and Power Limited, Tata Steel Works, Jamshedpur, Jindal Steel and Power Limited, Angul and GIZ, India. The presentation by SMC POWER Generation Limited explained the benefits achieved by installing online Hot Billet Charging through high speed conveyor, HMI PLC automation for Hot billet shifter to reduce reject of Billets, installing Hot Billet counter and installing water flow meter for accurate water measurement in rolling mill. The presentation by Nalwa Steel and Power Limited highlighted the benefits achieved by installing Iron Ore wet screening plant, installing Deshelar system, use of pellet, segregation of injection coal size, use of imported coal in DRI, and implementation of effective techniques in DRI. The presentation by Tata Steel Works, Jamshedpur explained the benefits achieved by installing thin slab caster and rolling, use of pellets and shift to alternate fuel for utilizing lean by-product gases, using solar energy & LED lights for the street and coal injection @ 200 kg/thm at blast furnaces. The presentation by Jindal Steel and Power Limited, Angul highlighted the energy savings achieved by modifications in DMCW pump at the power plant facility, raw water pumps, and makeup water pumps which led to an annual monetary savings of Rs. 40.78 lakhs, Rs. 30.72 lakhs and Rs. 39.85 lakhs respectively.

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Shri Sanjeev Jain with the panelists of the third technical session

The fourth technical session was focused on sharing of experience of the industry on implementation of innovative best practices and energy efficient technologies for the Iron & Steel sector, was Chaired by Shri A. K. Asthana, Senior Technical Expert, GIZ. The industries that shared their experience included TATA Sponge Iron Limited, Thermax, MCJ Energy Engineers Private Limited and AMREC Group. The presentation by TATA Sponge Iron Limited highlighted the energy savings achieved by replacing of Impeller of Kiln #2 ID fan motor (3.3KV, 260kW motor), replacing of under loaded LT motors with correct size motors of DE system of Kiln-1 & Kiln-3, VFDs for pump motors running in throttled condition, 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 and lighting control through timers.

The session also had presentations on technologies available for various operating areas viz. options to reduce carbon and energy intensity in steel sector by Thermax, best energy auditing practices in iron & steel sector by MCJ Energy Engineers Private Limited and energy efficient cooling towers by AMREC Group.

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Shri A. K. Asthana with the panelists of the fourth technical session

Technical sessions was followed by a panel discussion on future strategies to be adopted and need for promoting innovative, new and cutting edge technologies and cross-sectoral best practices. The panelists were the members of Sector Learning Group. The panelist briefly explained the key discussion points of the SLG meeting, which was held a day before the workshop (3rd March, 2016) and concluded that KEP can play an important role in facilitating policy discussions around PAT, particularly, as it is moving in to the next cycle where the iron & steel industry is expected to have new targets and more plants are expected to come under the ambit of PAT. Panelist also felt that KEP will be in a position to assist the industries to meet the new targets by bringing in international best practices and technologies.

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SLG members as the Panelists at the Panel discussion

On behalf of Bureau of Energy Efficiency and Institute for Industrial Productivity, Shri K. K. Chakarvarti thanked the top management of Godawari Power & Ispat Limited, in particular, Shri B K Agrawal, Managing Director, Shri Abhishek Agrawal, Executive Director, Shri Lakshman Prasad, Advisor (Mineral Resources and Environment) and the entire team of Godawari Power & Ispat Limited for extending their earnest support to the KEP initiative and pulling through an event of this scale. He also thanked all the speakers and delegates who participated in the workshop and thanked them for their comments and suggestions and assured that each will be given consideration so that future workshops will be even more of a success.

The workshop had participation from over 160 distinguished speakers, eminent Iron & Steel industry leaders, Government agencies, CREDA, Industry associations, technology providers, energy managers and auditors, and senior Industry professionals amongst many others.

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Participants at the 1st Iron & Sector Workshop under Knowledge Exchange Platform initiative

 

BEST PRACTICES IN ENERGY EFFICIENCY IN SPONGE IRON (IRON & STEEL) SECTOR
INAUGURAL SESSION (9.30 AM - 10.00 AM)
Welcome Address, introduction and expectations from the workshop Shri K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency
Special AddressShri Shailendra Kumar Shukla, Chief Executive Officer, Chhattisgarh State Renewable Development Agency (CREDA)
Special AddressShri Abhishek Agrawal, Executive Director, Godawari Power and Ispat Limited
Inaugural AddressShri Vivek Agrawal, Chief Operating Officer, Godawari Power and Ispat Limited
Vote of ThanksShri Lakshman Prasad, Advisor (Mineral Resources and Environment), Godawari Power and Ispat Limited
TECHNICAL SESSION I (10.00 AM - 11.30 AM): Best Practice Presentation by Industry Representatives
ChairmanShri Vivek Agrawal, Chief Operating Officer, Godawari Power and Ispat Limited
Energy Conservation Act and PAT Scheme by Bureau of Energy EfficiencyShri K. K. Chakarvarti, Expert Consultant
Price Forecasting for PAT and other Cap-and-Trade Markets by Climate Connect LimitedShri Chandan Kumar, Economist

Shri Harry Horner, Market Analyst
Best Practices adopted by Godawari Power and Ispat LimitedShri Ratnadeep Gupta, AGM
Best Practices adopted by Jindal Steel and Power Limited, RaigarhShri Kumar Rohit, Manager
TECHNICAL SESSION II (11.30 AM - 1.00 PM): Best Practice Presentation by Industry Representatives
ChairmanShri K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency
Best Practices adopted by M/s. BMM Ispat LimitedShri Y. Bhaskar Rao, Deputy Manager
Best Practices adopted by JSW Steel, Dolvi worksShri V. V. Gokhale, Senior Manager

Shri Yogesh Mhatre, Assistant Manager (E & A)
Best Practices adopted by Usha Martin Limited (Usha Alloys & Steels Division)Shri Bidhan Mandal, Assistant Manager

Shri Chiranjib Das, Assistant Manager
Automatic Tube Cleaning System (ATCS) by CQM-RAJ IndiaShri Aashish Sharma, Dy. General Manager - Sales & Business Development, CQM-RAJ India

Shri Sameer Gaur, Head Business Development, GK Infra Engineers
LUNCH (1.00 PM TO 2.00 PM)
TECHNICAL SESSION- III (2.00 PM - 3.30 PM) : Best Practices adopted by Industry Representatives
ChairmanShri Sanjeev Jain, Chief Engineer, Chhattisgarh State Renewable Development Agency (CREDA)
Coal Blending and its effects on Boiler Performance by GIZ, IndiaShri A. K. Asthana, Senior Technical Expert
Best practices adopted by SMC POWER Generation LimitedShri S. K. Singh, Manager-Instruments
Best practices adopted by Nalwa Steel and Power LimitedShri Vishal Vashishtha, Energy Manager

Shri Debasis Roy, Manager-DRI
Best Practices adopted by Tata Steel Works, JamshedpurShri Rajiv K. Chittrey, Senior Manager, Fuel Management Department
Best Practices adopted by Jindal Steel and Power Limited, AngulShri Jay Prakash Choudhary, Energy Manager
TEA BEAK (3.30PM -3.45PM)
TECHNICAL SESSION- IV ( 3.45 PM - 4.45 PM) : Best Practices and Energy Efficient Technologies for Sponge Iron Sector
ChairmanShri A. K. Asthana, Senior Technical Expert, GIZ
Best Practices adopted by TATA Sponge Iron LimitedShri Bijay Kumar Agrawal, Head - Electrical Maintenance
Options to reduce carbon and energy intensity in Steel sector by ThermaxShri Vivek Taneja, Head- Business Development
Best practices in Iron & Steel sector by MCJ Energy Engineers Private LimitedShri Moolchand Jain, Managing Director
Energy Efficient Cooling Towers by AMREC GroupShri Shailesh Harani, Managing Director
PANEL DISCUSSION (4.45 PM - 4.55 PM) : SLG MEMBERS
Future Strategies to be adopted; need for promoting innovative, new and cutting edge technologies and identify the areas for sharing of Cross- Sectoral Best practices.
CONCLUDING REMARKS (4.55 PM - 5.00 PM) Shri Lakshman Prasad, Advisor [Mineral Resources and Environment], Godawari Power and Ispat Limited &

Shri K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency

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