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Ispat Industries Limited

Apr 07, 2018

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    Confederation of Indian Industry

    PreliminaryGreen Survey

    atISPAT Industries Limited

    CII Sohrabji Godrej GreenBusiness Centre

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    Confederation of Indian Industry

    At the outset

    Thank you for

    Opportunity

    Hospitality

    Total Support

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    Confederation of Indian Industry

    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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    Confederation of Indian Industry

    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

    Confederation of Indian Industry

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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

    Confederation of Indian Industry

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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

    Confederation of Indian Industry

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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

    Confederation of Indian Industry

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    Confederation of Indian Industry

    Mission on Sustainable Growth

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    Confederation of Indian Industry

    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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    Confederation of Indian Industry

    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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    Confederation of Indian Industry

    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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    Confederation of Indian Industry

    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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    Confederation of Indian Industry

    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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    Confederation of Indian Industry

    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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    Confederation of Indian Industry

    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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    Confederation of Indian Industry

    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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    Confederation of Indian Industry

    Core Purpose

    To promote and champion

    conservation of Natural resources in

    Indian Industry,

    without compromising on

    high and accelerated growth

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    Confederation of Indian Industry

    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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    Confederation of Indian Industry

    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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    Confederation of Indian Industry

    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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    Confederation of Indian Industry

    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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    Confederation of Indian Industry

    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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    Confederation of Indian Industry

    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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    Confederation of Indian Industry

    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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    Confederation of Indian Industry

    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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    Confederation of Indian Industry

    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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    Confederation of Indian Industry

    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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    Confederation of Indian Industry

    Green Audit

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    Confederation of Indian Industry

    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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    Confederation of Indian Industry

    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

    Confederation of Indian Industry

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    Training (awareness) programme

    To involve plant team fully in Green

    audit

    Coverage

    Methodology

    Actual implemented Case studies

    Confederation of Indian Industry

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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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    Confederation of Indian Industry

    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

    Confederation of Indian Industry

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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

    Confederation of Indian Industry

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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

    Confederation of Indian Industry

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    Lighting

    Optimization of lighting feeder voltage

    Energy efficient lighting generation

    system

    Better Lighting Distribution System

    Installation of LEDs Lamps

    Confederation of Indian Industry

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    Confederation of Indian Industry

    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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    Confederation of Indian Industry

    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

    Confederation of Indian Industry

    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

    Confederation of Indian Industry

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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

    Confederation of Indian Industry

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    Achievements

    950 Detailed Audits Conducted

    Rs. 1950 Million Savings Achieved

    Confederation of Indian Industry

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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

    Confederation of Indian Industry

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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

    Confederation of Indian Industry

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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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    Confederation of Indian Industry

    Thank you