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PreliminaryGreen Survey
atISPAT Industries Limited
CII Sohrabji Godrej GreenBusiness Centre
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At the outset
Thank you for
Opportunity
Hospitality
Total Support
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Centre of Excellence for Energy, Environment, Green Buildings,Renewable energy, Water & Climate change activities in India
CII Sohrabji Godrej Green Business Centre,Hyderabad
A unique Public Private Partnership( CII, Govt of Andhra Pradesh, USAID and Pirojsha Godrej Foundation )
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Presentation - Agenda
Objective & purpose of the study
About Mission on Sustainable Growth
Green audit Focus areas
Energy efficiency improvement Water management
Waste reduction
Renewable energy
GHG Inventorisation
Office Buildings Green aspects
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Objective
Ispat Industries Limited Should
Achieve maximum benefits
Energy efficiency, water, waste
reduction, renewable energy
Develop an image & achieve the Confederation of Indian Industry
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Approach
Team work
Combined efforts of ISPAT and
CII-Godrej GBC team
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Purpose of the Preliminary Survey
To understand the plant
Identify the focus areas & Estimate the benefits
To understand the customer needs
Define Scope of Work Estimate the time required for detailed Green
audit
Develop a detailed proposal for plant
personnels consideration
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Previous Green initiatives at ISPAT
Many projects have been implemented in energy efficiency
improvement, water & waste minimisation
One of the most efficient and compact integrated steel plant
Waste heat recovery system hot air utilisation for sintering process
Optimisation of compressed air system & minimisation of number of
compressors
Optimisation of operating pressure of compressed air system
Efficiency improvement in major pumping systems
Periodic water audits and efforts for minimising water consumption
almost 100% utilisation of metallic wastes
Plantation campaign
Excellent Work done By ISPAT Industries Limited team
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Open Mind and Commitment
In spite of successful in-house
efforts - CII invited
Indicates open mind and
commitment of plant personnel
towards Greening the plant
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Mission on Sustainable Growth
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Background
For India to achieve a DevelopedCountry status
Need to maintain high GDP growth rates
Flipside of higher growth rates
Increased use of natural resources
Energy, Water, etc.
Increased emissions and discharges
Need to focus on Ecologically Sustainable growth
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Ecological Footprint
Ecological Footprint Measure of how much
land and water is needed
to produce the resourceswe consume and to
dispose of the waste we
produce
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Global Ecological Footprint
0 . 0
0 . 5
1 . 0
1 . 5
1 9 6 1 1 9 6 6 1 9 7 1 1 9 7 6 1 9 8 1 1 9 8 6 1 9 9 1 1 9 9 6 2 0 0 1
Num
bero
fE
C O 2 p o r t io n o f h u m a n i ty 's E c o lo g i c a l F o o t p r i n t
H u m a n i ty 's fo o d , fi b e r , b u i l t-u p l a n d a n d n u c l e a r F o o tp r i n t
H u m a n D e m a n d o n B io s p h e re :
E c o lo g i c a l F o o t p ri nt 1 9 6 1 - 2 0 0 3
Source: Global Footprint Network, USA
CO2 Portion of Humanitys Ecological Footprint
Humanitys food, fiber, built-up land and nuclear footprint
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INDIAS ECOLOGICAL FOOTPRINT
Source: Global Footprint Network, USA
India Footprint, Biocapacity and GDP
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1961 1966 1971 1976 1981 1986 1991 1996 2001
Globalhectaresper
0
100
200
300
400
500
600
GDP
p
ercapita.
constant2
Footprint
Biocapacity
GDP
Ecological DebtGrowing over time
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Debtors Creditors
Ecological Debtor & Creditor Countries
Footprint > 1.5 Biocapacity
Footprint = 1.0 - 1.5 Biocapacity Biocapacity = 1.0 - 1.5 Footprint
Biocapacity > 1.5 Footprint
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3/4 th ofIndia,Pakistan,West Asia,North Africaand NorthChina will be
in the throesof absolutewaterscarcity overthe coming25 years.
Source: International Water management institute
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Water Indian Scenario
Decreasing per capita availability
5177 m3 in 1951 has dropped to 1869 m3 in 2001
Estimated to further decline to 1341 m
3
by 2025
85 - 90 % of Indias surface water resources are
polluted
Reason - Only 10 % of waste water generated is treated
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Need of the Hour
Vital need
Improve efficiency
Reduce resource intensity
India to focus on Sustainable Growth
Towards realizing this objective, CII has
outlined a new activity
Mission on Sustainable Growth under the
chairmanship of Mr. Jamshyd N Godrej
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Core Purpose
To promote and champion
conservation of Natural resources in
Indian Industry,
without compromising on
high and accelerated growth
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Objectives
Involve top management
Seek voluntary commitments & self targets frommember companies
Partner and work together, in realizing the
objectives of MSG
Campaign launched for signature by
companies
CII - Code for Ecologically SustainableBusiness Growth
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Signature Campaign
CEOS meet
Mumbai, Delhi, Chennai,
Bangalore, Kolkata, Hyderabad
Progress
330 CEOs have Signed the code
Includes Tata steel, Tata power,
Infosys, Godrej, Wipro, Ashok
Leyland, Volvo, ABB
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Mission on Sustainable Growth
CII Godrej GBC will handhold signatories of Codefor ecologically sustainable business growth
Target : 500 signatories by 2009
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Ten Natural Commandments
1. Specific - Water & Energy reduction ( 2-6%)
2. Waste reduction ( 2-6%)
3. Renewable energy increase (2-10%)
4. Specific - Green House Gas Emission reduction
(2 6%) and explore opportunities through
CDM & other carbon exchange programs5. Recycling of material increase (2-10%)
6. Rain Water harvesting increase (2-10%)
Code for Ecologically Sustainable BusinessGrowth
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Ten Natural Commandments . . .7. Life cycle assessment of new products and
technologies
8. Green Purchase Policy
9. Product stewardshipprograms
10.Other natural capitals reduction ( 2-6%)
Also to have commitments to achieve ISO9001,
ISO14001, OHSAS18001, SA8000, Green
Buildings, Eco Labels etc.
Code for Ecologically Sustainable BusinessGrowth
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CII Code for Ecologically Sustainable business growth..
Being cognizant of the need of sustainable growth and dwindling stock of natural capital, we commit
ourselves to the attainment of the following Ten - Natural Capital Commandments.
1. Reduce specific consumption of water and energy by 2 - 6% every year over next ten years.2. Reduce specific generation of waste and reduce the quantum of waste going to land fills by 2-6% every year over next ten years
3. Increase use of renewables including renewable energy by 2- 10 % every year in place ofnon-renewables over next ten years
4. Reduce emission of green house gas emissions and other process emissions by 2 - 6% everyyear over next ten years and explore opportunities through Clean Development Mechanism(CDM) and other Carbon Exchange Programs
5. Increase use of recyclables and enhance recyclability of resources embedded in the product
by 2 10 % every year over next ten years6. Increase the share of harvested rain water in overall annual use of water by 2 10 % every
year over next ten years
7. Incorporate life cycle assessment criteria for evaluating new and alternative technologies &products
8. Strive to adopt green purchase policy and incorporate latest clean technologies
9. Take lead in promoting and managing product stewardshipprogram, by forging partnershipswith businesses and communities
10. Reduce depletion of natural capital which is directly attributable to companys activities,products and services by 2 10 % every year over next ten years.
We also commit to demonstrate attainment of these commandments in our pursuit to certifications
such as ISO 9001, ISO 14001, OHSAS 18001, SA 8000, Green Buildings, Eco Labels and the like.
Date : Signature :
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CII Code
Reduction target is up to the
individual plant / section
Based on the level of technology
Energy intensity
Few of the commandments can be
omitted, if it is not applicable
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1. Handholding companies Developing baseline and voluntary target setting
GHG Inventorisation
Assist in identifying improvement opportunities in terms of
energy, water, waste, materials etc.
Facilitate in implementing identified projects for reducing
energy, water etc.
Develop a system for continuous monitoring
2. Assisting development of Green Purchase Policy
Role of CII
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2. Collating and disseminating international bestpractices
Best Practices from USEPAs Climate Leaders program
Best Practices from other APP countries China, Korea,
Australia and Japan
3. Ecological Footprint study for India, specific sectors
and individual enterprises
Serve as a tool for monitoring the environmental impact of
the organization
Role of CII..
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Asia Pacific Partnership (APP)
CII is taking up an APP project to foster ecologically sustainable
business growth in India with the support of US
United States Environmental Protection Agency (USEPA)
Sharing experiences and best practices of Climate Leaders
Program
World Resources Institute (WRI)
GHG Accounting & Reporting
New Ventures India
Global Footprint Network & World Wide Fund (WWF)
Footprint Study
Swedish Environmental Research Institute (IVL)
Cleaner Production & Water recycling
International Linkages
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Green Audit
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Approach for Green audit
Start with training programme
Energy efficiency
Water management
Waste minimisation
Energy efficiency improvement
Focus on No / marginal investment projects
Study of major auxiliary equipment in all plants
Utilities compressors & pumping systems
Thermal systems
Office buildings
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Approach for Green audit
Water Audit
Waste minimization study
GHG inventorisation
Training
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Benefits of Detailed Energy Audit
Identification of specific improvement
projects energy, water, waste reduction
etc.
Rs 200 Lakhs
Payback period 2 years
Guide Lines to sustain and making
Green as an on going activity
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Training (awareness) programme
To involve plant team fully in Green
audit
Coverage
Methodology
Actual implemented Case studies
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Training (awareness) programme
Energy efficiency - 2 days
Fans
Centrifugal pumps
Compressors & air dryers
Furnaces
Electrical Motors
Distribution
Lighting
GHG Inventorisation
Water management - day
Water balancing
Consumption reduction, reuse & recycle methodologies
Waste management - day
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Energy Efficiency study
Focus on no / marginal investment projects
Operational fine tuning
Minimal modification of the equipment
Facilitation of brain storming amongst the plant team
for identifying improvement projects
Will be taken up as part of the training programme
Coverage
Both electrical & thermal systems
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Energy Efficiency study
Major focus on energy saving opportunities inUtility equipment & auxiliaries of individual
plants
Sintering plant
Sponge iron plant
Blast furnace
Steel melting shop
Caster & tunnel furnace
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Fans & BlowersPerformance of all major fans will be studied
Flow, pressure & power consumption measurements
Estimation wherever measurement not possible
Operating efficiency
Operational fine tuning of fans
Further optimisation of fans with VFDs
Reducing system resistance
Possibility of reducing the suction side pressure drops
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Pumps
Potential areas for study all cooling water pumps &
utility pumps
Estimation of operating efficiency of major pumps
Possibilities of improving operating efficiency
Matching pump head with system resistance Fine tuning
including impeller trimming
Improved Controls application of VFCs & VFDs
Application of hydraulic coatings
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Air compressors & compressed airsystem
Further optimisation of compressed air pressure
Compressed air utilisation at the user end
Pressure drop
Process air & instrument air requirement
Demand & supply side management systems
Optimisation of compressors operation load
sharing
Study of HOC dryers and improvement
opportunities
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Motors
Optimum loading
Energy Efficient Motors
Energy Efficient Control Systems
Automatic Star Delta Star converter
Soft Starter cum Energy Saver
Interlocking
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Lighting
Optimization of lighting feeder voltage
Energy efficient lighting generation
system
Better Lighting Distribution System
Installation of LEDs Lamps
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Thermal systems
Study of thermal systems - major focus on
increased heat recovery opportunities
Heat recovery systems in sintering plant
Shaft furnace & reformer in sponge iron plant
Tunnel furnace air heater performance
Blast furnace & SMS Long term effort jointly by
ISPAT & CII-Godrej GBC
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Water Management
Comprehensive water balance of the units
Process water optimisation
Possibility of reuse & recycling of water
Domestic water optimisation Efficient fixtures, taps, faucets
Water less urinals
Water treatment for process water Treatment at generating point
Reduction of operating cost
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Waste minimisation
Already significant efforts taken forminimising metallic wastes
Study of waste generation
Waste utilisation
Reuse & recycling opportunities
Utilisation by external parties
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Methodology
Commence on acceptance of proposal Training programme
Senior plant person - Coordinator
Initial meeting - Specific approach Team formation
Field work
Data collection Measurements
Trials if required
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Identification of proposals
Discussion with all concerned
Presentation Report
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Methodology
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Report Coverage
Description of the Projects Energy,
water, waste reduction etc
Projects description
Cost Benefits
Back-up Calculation
Supplier Addresses
Format for Monitoring
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Role of CII-Godrej GBC
A Catalyst / Facilitator role Complementing in-house activities
Convincing & Quantification of the ideas
Assisting in implementation - Monitoring,Identification of Vendors, etc.,
Implementation of Projects
Reap the benefits
Role of the unit
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Achievements
950 Detailed Audits Conducted
Rs. 1950 Million Savings Achieved
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CII-EMC Achievements
Recipient of
National Best Energy Auditor
Award
1997-98, 98-99, 99-2000,
2000-01 & 2001-02
Fifth successive year Instituted By
PCRA, Govt. of India
Confederation of Indian Industry
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CII & steel plantsSteel Plants
Jindal steels Ltd, Hizar
Hospet steels
Essar steels, Vizag
Orissa sponge iron Ltd
Non ferrous metals
Vedanta group of companies Sterlite copper, BALCO, MALCO,
Konkala Copper- Zambia, Ararat Gold recovery, Hindustan zinc
National Aluminium Company Ltd
Aditya Birla group of companies Hindalco Industries Ltd,
Hirakud, Belur, Taloja
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D ISPAT Industries Limited has done well in the
past
D
Committed team of plant personnel
D Preliminary survey reveals
Further potential : Rs. 150 Lakhs
Attractive paypack period : 2 Years
To sum up
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D Detailed Green audit can help in tap
the potential
D CII can assist in conducting Detailed Green
audit
D Team work can enhance the benefit
Confederation of Indian Industry
To sum up
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Thank you