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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
PUBLIC INFORMATION
Pranab Sarkar
Vice President Energy
Energy Intelligence Helps JSW Steel Monitor Energy KPIs and
Reduce Usage Rockwell Automation Solutions Help JSW Steel to Monitor and Manage Gas, Water and Electricity Consumption Across the Facility –
Capture, Histories, and Analyze the Energy Usage
Agenda
JSW Steel at a glance
Project Background, Drivers, & Challenges
Reports, Dashboard & Overview reports
Benefits & Lessons learned
Future Road Map
Introduction Video
JSW Steel at a glance
JSW Steel is India’s fastest growing steel conglomerate.
It started in 1999 with 1.67 Mtpa integrate plant using Corex-BOF, but latter added BF-BOF & DRI-EAF route for Iron and steel making.
Today it is single location 12 Mtpa of steel mill & is largest single location plant in India.
It operates 20 Mtpa Ore beneficiation Plant. Sintering capacity is 32000 TPD & Pelletizing capacity is 20000 TPD.
Coke making is 4.7 Mtpa. 3.5 Mtpa is through By Product Recovery route with CDQ and 1.2 Mtpa of Heat Recovery with power plant.
Iron making facilities are 2*2400 TPD Corex, 4 BF’s of 1300 (Being upgraded to 2300), 1800 & 2*4013 Cubic meter respectively.
JSW Steel a glance (Contd …)
SMS comprises of 3*140 Tons of converter in SMS – I, 4*175 Tons converter in SMS – II and 1*160 Tons EAF in SMS – III.
Down stream comprises of HSM of 3 & 5 Mpta, BRM of 1 & 1.2 Mtpa each, WRM of 0.6 Mpta & 2 CRM of 1 & 2 Mtpa.
It operates 155 MW of waste heat power Plant, 170 MW of Gas based power plant.
It operates 11255 TPD of Oxygen plant on BOO basis.
A 1600 TPD micro pellet unit for handling waste fines on BOO basis.
A pilot plant for converting slag as alternative to river sand. And
A 0.2 Mtpa Mills Scale briquetting unit.
Agenda
JSW Steel at a glance
Project background, Drivers, & challenges.
Reports, Dashboard & Overview reports
Benefits & Lessons learned
Future Road Map
Why Energy online ?
Energy comprises 40-45% of total cost of steel production in India
A one percent reduction in energy consumption improves bottom line by 0.45%
The foremost requirement of reduction programme is to establish actual consumption pattern.
Identify gaps between achieved and benchmark.
Needed detailed gap analysis and trend analysis. Assign balanced cost and bridge the gap.
A plant wide energy scheduling and accounting solution was necessary. … and that explains what is energy online.
5 levels of Energy Online – JSW Approach
Optimization models.
Regulate power use based on sparks from EMS .
Energy use control based on EMS
Heat Arrest and loss capture (HALC) based on input data and on line energy balancing system.
Comprehensive energy monitoring, Stage wise, balanced input and output for entire operation.
5.45 GCal /TCS
6.63 GCal /TCS
Key Deliverable of Energy Online
EMS identifies gaps between energy generation, transmission & distribution and guides EMC to optimize the use.
Trend analysis indicates the need in next hour and shift to divert excess to sink and if warranted avoid inefficient uses.
Dashboards provide techno economics of best alternatives and accordingly EMC decides the priority.
Similarly power Dashboards provide sparks for idle running of motors to put them on idle or stop.
It also helps in reducing peak power during start of large loads with high initial torque by switching off or reducing not important loads.
Challenges
Ensure correctness of data being gathered and what is critical.
To understand the correlation between the data and the production – thereby the impact of the data on the production.
To communicate with shop server, they have various configuration.
Transmission mode of data (A plant spread in 10 thousand hectares)
Passing through impossible obstacles, tracks, Gas line Roads of the
running plant.
Energy Online launched
Energy On line was launched in 2007.
Schneider Electric, Honeywell, Automation engineers and Rockwell Automation® were sent the RFQ and JSW wish list.
4 Key Criteria: Technology, Compatibility with existing system, Ease of installation & Cost were parameters for evaluation.
Rockwell Automation was selected as they matched competitors in 3 criteria, they were L2 & 100% matching our wish list.
Rockwell Automation became natural choice as
– FactoryTalk® architecture allowed for integration to basic automation and was compatible to various automation systems.
– Future scope of expanding.
– ROI was only 6 months.
Sinter Plant # 2, 3 & 4 & LCP#11
WRM , BRM-I & Process Blr#1
BRM #2 & SMS#3
CPP #1
Blast Fce # 3&4 Gas Holder
System Architecture- FactoryTalk Suite of Products Delivering the Connected Enterprise
Energy Data Source
Context
Information
Decision
Pellet Plant # 1& SP#1
CRM # 2 & Process Blr#3
Corex Unit 1&2
Blast Fce # 1&2
Blast Fce # 3&4
Pellet Plant # 2
Coke Ovens
Oxygen Plants
Blast Fce #1&2 Gas Holder
LD Gas Holders
HSM - I
CPP #2 & Process Blr #2
CPP #3,4 & JSWEL
CRM# 1
LCP Kiln # 1 to 10 & 12
Main Electrical sub Station
SMS # 1&2
HSM - II
GMS# 4
GMS# 1
GMS# 2
GMS# 3
DRI
EMC Display
Dy. MD President
(Oprn)
VP Energy
Steel Business AVP
Energy
Vjnr
32 systems
captures 700
parameters
across plant
Server
1 Version
of Truth
Overview of System Architecture
MicroLogix™ & ControlLogix® across the network from different location.
FactoryTalk® Historian was used to collect data
FactoryTalk® VantagePoint EMI to convert the data to Actionable Information
– Advanced portal, reporting, and analytics tool
Reports Specified:
– Shop wise Gas Consumption Report
– Energy Utilization Report (Gas generation, Liquid stocks of Ar,o2 N2 details, LPG day consumption)
– FactoryTalk VantagePoint Trends ( Pressure, Flow, Temperature)
FactoryTalk® AssetCentre to manage automation Assets –
– A complete record of who made what change in the PLC’s
JSW Steel At a Glance
Project Background, Drivers, & Challenges.
Reports, Dashboard & Overview reports
Benefits & Lessons learned
Future Road Map
Agenda
Energy Center in Action- EMD control room
Accounting of By-Product fuel gasses
The On-Line Fuel Values
On line accounting of gaseous fuels
Real Time Data helps in Effective Manage & Control
Real Time data helps in effective control
Sample Reports and Trend- Better Analysis Real Time & Historical data
Trend Analysis Report Summary Report with Trend
Gap analysis based on Real Time & Historical data Better Analysis – Helps Decision Making
Stage BM Actual Gap Analysis
Coke Making
U/F Heat Rate
0.55
GCal/TP
0.62GCal/TP 0.07
GCal/TP
More Coking time
Agglomeration
Solid Fuel Rate
51 Kg/TP 62 Kg/TP 11 Kg/TP High Alumina in Base Mix
BF Coke Rate 430
Kg/TP
452 Kg/TP 12 Kg/TP Low HBT due to less rich
fuel in stove heating.
High Oxygen
blowing Rate
52
m3/THM
58 m3/THM
6 m3/THM High Al in HM
RHF Heat Rate 0.28
GCal/TP
0.29 GCal/TP
0.01GCal/T
P
High Cold charging due to
mismatch in planning
High Power
Rate
480
KwH/TCS
480 KwH/TCS 480
KwH/TCS
High idle running hours
JSW Steel at a glance
Project Background, Drivers, & Challenges.
Reports, Dashboard & Overview reports
Benefits & Lessons learned
Future Road Map
Lessons Learned
Planned Happened Learning
Monitoring of generation
& consumption suffice
accounting of fuel
Generation does not
match flare+consumption
in practice
Small unaccounted
consumers. It is
necessary to measure
To ensure micro control it
is important to measure
heat rate of each micro
product.
On line CV monitoring for
correct accounting of heat
input is essential.
Online CV, flow &
software for computing
heat input in a dashboard
is very effective.
By only accounting,
limiting flare to nearly
zero.
The wide fluctuations
both in generation &
consumption can not be
totally managed
Sinks for dumping fuel
and withdraw, almost
instantly became a major
requirement.
Benefits
Pre Energy Online Post Energy Online
Gas Flaring to the tune of 200 G Cal/Hr or
0.24 million INR/Hr
Flaring reduced to 30 G Cal/Hr or 0.036
million INR/Hr
Though accounted, many uses of energy is
not optimized, but not possible to pinpoint.
By gap analysis based on trends helps to
identify wasteful use of energy.
The identification of non productive fuel
supply were not identifiable
It is easily identifiable
Delay tactics were not possible to
implement as dashboards. Were not
available to give sparks for idle running
Sparks from online monitoring have
reduced the consumption by 2%
Every authorized user can access the data he needs from various data sources- Take Corrective
action, has ability to make decisions based on Real time data with details
Specific Energy Consumption
Relentless
efforts to
reduce
Specific
Energy
Consumption –
inspite of
switching to
poor grade iron
ore with high
alumina &
silica content
in 2012-13.
6.41 6.22 5.98
6.77 6.46
6.22
5.26
5.85
6.81
7.49
8.49
9.26
0
1
2
3
4
5
6
7
8
9
10
1 2 3 4 5 6
Axis
Tit
le
Years
SEC and Production
SEC Prodn
JSW Steel at a glance
Project Background, Drivers, & Challenges.
Reports, Dashboard & Overview reports
Benefits & Lessons learned
Future Road Map
Agenda
Future Road Map- Mobility Providing Information to the Users-When and Where they need
Optimization by linear programming.
7
EMD
6b
5b
MSDS
5a
6a Shops
PPC
2 3 4
1
S&M
PP
Pur
JSW EL
?
?
1. Order Book Status
2. Plant Capacity Availability
a. Shutdown Plan
b. Plant Capacity
3. Hot Metal Availability
4. Raw Material Availability
5. Energy Availability
a. Electricity
b. Gases & Oxygen
6. Shop-wise Energy Requirement
a. Electricity
b. Gases & Oxygen
7. Actual Production
PP. Production Plan
Data Items
Sales & Marketing
Purchasing
JSW Energy Limited
Production Planning & Control
Energy Management Department
Main Step Down Station
Departments
S&M
Pur
JSW EL
PPC
EMD
MSDS
Energy Requirements not
considered during Production
Planning
Accept ad hoc Sales orders
Shops responsible for meeting
production plan only
Production Plan made available
to shops alone, and only on the
day of the production
Shop Maintenance Planning by
individual shops alone
Issues related to daily deficit or
excess energy, discussed in
daily morning HoD meetings
Spikes and Valleys in Energy Requirement
Frequent Changes to Plan, sometime during the production day
Allows for shops to not address idle load and hence carry higher specific consumption
No visibility of plan and hence potential issues beyond 2-3 days for all stake holders
Reactive Production Planning by PPC & Energy Planning by MSDS & EMD
Scalability issues possible in the future
Optimization by linear programming.
Optimization by linear programming. Maximizing the
contribution profit in the short & long
term
Greater production planning rigor &
hence scalability of planning process
Better shop shut-down planning and hence maximizing the utilization of
mills
Optimally use the facilities like the
oxygen plant
Meet the various demands and
commitments made to customers
Reducing the Specific Energy Consumption
Integration of energy data into
production planning & hence
better energy balance
Rockwell Automation’s Presence @ JSW Steel-
Tornagallu, Bellary. » Blast Furnace 1 – 2501 M3 Capacity – Under execution
» Blast Furnace 2 – 1600 M3 Capacity - 2007
» Blast Furnace 1 &2 – 1000 Tags FT Historian - 2010
» RMHS – 4 MT & 7 MT Department – 1998 & 2007
» Coke Oven 1 &2 - Year 1999 & 2005
» Pellet Plant 1 – Balling Disc application – Drives - 2011
» Steel Melting Shop 1,2 – Caster 1,2,3 &4 Drives & Automation – 2007,2008,2010
» Tunga badra Dam Water Pumping scada - 2011
» Almatti Dam Water pumping scada - 2012
» Laddle Heating furnace LHF4 – 2008
» Mill supply & Distribution system – MSDS Scada – 1999
» Lime Klin 9,10,11 & 12 – 2013/2014
» Energy Management Centre – 4 MTPA/7 MTPA & 10 MTPA
» JSW Praxair
» JSW Energy – DM Water Plant
» JSW Cement – 0.55 MT Cement Plant
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. RSTechED 2014 @RSTechED #RSTechED
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