JSW Steel Ltd

(A Unit of O.P. Jindal Group of Companies) A fastest Growing Steel plant in the country Achieved annual turnover of Rs.19457crores Won Prestigious Steel Ministers Trophy award for its Excellence in steel industry On completion of Project Falcon, JSW Steel will become largest steel plant in single location

Saving in Everything We Do

Sep-2010

JSW : Process Flow

Non - coking coal Iron ore Coking coal Fluxes

Lump ore

Beneficiation

Coke oven

Pelletization Sintering

Lump ore

HMPT Billet Caster Wire Rod / Re Bar Mill

Corex

Blast furnace

Converter

LHF, RH

Slab Caster

HSM

CRM

Saving in Everything We Do

Sep-2010

Uniqueness
100% stamping in both recovery and non recovery type Coke oven batteries Energy Efficient Corex hot metal making unit Highest No. of gas holders (6 No.s) Largest Corex gas holder (capacity: 1,00,000Nm3) Handling 4 types of Gases Common CV of 1850kcal/Nm3 for all units Captive power plant based on Waste heat generating 65MW power Captive power plant based on 100% byproduct gases Zero consumption of Petroleum fuel for Iron making Hot charging of slabs more than 65% in Hot strip Mill furnace All 3 furnaces operating with Pulverized coal injection Only Steel plant to deliver CDM benefits Largest Blast furnace , Largest HSM in India
3

Saving in Everything We Do

Sep-2010

l / T

Sp Energy Consumption
7.2 7 6.98 6.847 6.704 6.6 6.495 6.4 6.2 6 2006-07 2007-08 2008-09 Y ear 2009-10 E pec ted x 2010-11 6.2

6.8

Reduction in Sp Energy Consp over 2008-09 is 3.12%

Cost Analysis Sl No 1 2 3 Description Specific Energy Rate Total Crude Steel Produced Gcal Cost UOM Gcal/Tcs Tons Rs/2008-2009 6.704 3082142 1475 2009-2010 6.495 5257286 1353

v Savings with respect to Energy Consumption over 2008-2009 is Rs 148.68 Cr

Saving in Everything We Do

Sep-2010

Gap Analysis w.r.t Global Best

Gap Analysis Sp. Energy of Similar plant POSO, South Korea

5.20Gcal/Tcs

Sp. Energy of Similar plant JSW Steel, Vijayanagar Works Gap

6.495Gcal/Tcs

1.295 Gcal/Tcs

Saving in Everything We Do

Sep-2010

Gap Analysis (Contd..)

Sl No

Description

POSCO

JSW

Gap

Effect in Gcal/Tcs

Remarks

Hot Metal rate

933

1027

94
Kg/TLS

0.38

To reduce hot metal rate JSW Steel is installing DRI Plant Projects are on for implementation in boilers Project are under implementation

BF gas Utilization CDQ in recovery type coke oven Heat recovery from flue gas stoves and sinter cooler

100%

83%

17%

0.322

100%

Nil

100%

0.186

100%

Nil

100%

0.123

Project are under implementation

Total Gap

1.011 Gcal/Tcs 6

Saving in Everything We Do

Sep-2010

Energy Conservation Initiatives 2009-10.

Coke ratio at Corex was lowered by 6.7%. This was achieved by better heating regime and consistent coal availability. Coke rate at blast furnace was lowered by 9.3% by increasing the PCI. This was achieved by increased availability of Blast furnace operation. LCP heat rate was lowered by 5.6% and power rate was lowered by 6.8%. This has been achieved by increased availability of gases to Calcining plant. LD gas recovery at BOF has improved by 1.7%. It was possible by 100% gas holder availability and installation of gas boosters. 5. HSM heat rate was lowered by 4.2% and power rate was lowered by 11.9%. This was achieved by eliminating idle hours of HSM due to non availability of gas and by ensuring more availability of gas to reheating furnace. Mills have stabilized its operation due to over all increase in value added products. Power rate of CRM has lowered by 13.25% Corex gas utilization has improved from 97% to 97.94% by better gas management. Waste heat utilization at non-recovery type coke ovens waste heat recovery power plant was improved and there was increase in power generation from 72.39MWh to 106.23MWh also with increased byproduct gas utilization Gas based captive power generation has increased with better gas management.

Saving in Everything We Do

Sep-2010

Energy Saving Projects

Annual Electrical Savings achieved Rs Milli on Annual thermal savings In terms of Quantity or Gcal/Tcs. 105 Gcal of energy recovered Annually 550 tons of LPG is being saved. Annually 730 tons of LPG is being saved. 30,000 Nm3/hr of gas utilized Total Inve Annu st. al Mad Savi e ngs

Sl Year of Title of Energy Saving N Implementa project implemented o tion

Units Million

Rs Rs Rs Milli Millio Millio on n n

Third Booster to 1 improve LD gas recovery.

2007-08

98

98

45

2 Sand heating in BOF.

2007-08

24.8 24.8

0.12

Replace of LPG by 3 Byproduct gas in Boiler Burners. BF Gas Holder for 4 improving utilization of BF Gas

2007-08

32.9 32.9

2007-08

113

113

220

Saving in Everything We Do

Sep-2010

Energy Saving Projects

Sl No Title of Energy Saving project implemented Annual Electrical Year of Savings achieved Implementat ion Rs Units Millio Million n Annual thermal savings In terms of Quantity or Gcal/Tcs. By stabilization of BF gas pressure with the help of BF gas holder Total Annua Invest l . Made Saving s Rs Rs Rs Millio Million Million n

Captive power generation has increased from 86.87 MWh to 93.35 MWh.

2008-09

6.48

176.5

176.5

Nil

Waste heat utilization and by product gas utilization has improved at Non recovery type coke oven based captive power plant resulting in increase of power generation from 59.16 MWh to 72.38 MWh By effective control of off blast and increased plant availability increase in the CDI rate by 18.39% over the last year LPG consumption has been reduced from 12.61 Tons/day to 10.9 Tons/day by replacing LPG by Corex gas in BF flare stack pilot, sand heating system in BOF and in BF boiler by modifying the Corex gasline

2008-09

13.22

360.2

360.2

Nil

2008-09

Energy Consumptio n has increased from 0.377 to 0.464 Gcal/tcs. Energy Consumptio n has reduced from 0.015 to 0.0125 Gcal/Tcs.

262

262

Nil

2008-09

24.59

24.59

25

Saving in Everything We Do

Sep-2010

Energy Saving Projects

Sl No Title of Energy Saving project implemented Annual Electrical Year of Savings achieved Implementat ion Rs Units Millio Million n Annual thermal savings In terms of Quantity or Gcal/Tcs. Energy Consumptio n has reduced from 1.455 to 1.393 Gcal/Tcs. Rs Millio n

Total Annua Invest l . Made Payback Saving months s Rs Rs Million Million

Corex gas utilization has been improved from 93% to 94.18% by modifying the controls in flaring system LD gas recovery increased by 45.47% over the last year. This has been achieved by taking LD gas holder capital repair and changed the delivery mesh and also additional booster has also been installed to take care of LD gas transport during booster shutdow Replacement of high pressure high CV corex gas by low pressure low CV BF gas for Ore Drying Furnace

2008-09

1003

1003

0.4

0.14 days

10

2008-09

Energy Consumptio n has reduced from 0.190 to 0.132 Gcal/Tcs.

234

234

Within 2 days

11

2009 10

Energy Consumptio n has reduced from 0.015 to 0.012 Gcal/Tcs 60,000Nm3/ Hr Flared gas is used. This has enabled to generate and use additional 125,000Nm3 /Hr Mixed gas

73.58

73.58

30

5 months

12

Interconnection of 4mTPA7mTPA BF gas line network for ensuring BF gas to CO#3, even during shut down of BF#3 -7mTPA unit.

2009-10

367

367

90

3 months

13

Increasing BF #3 Gas holder pressure from 1000mmWC to 1085mmWC

2009-10

735

735

0.25

1 day

Saving in Everything We Do

Sep-2010

10

Team work in Encon 2009-10

Encon Team work
Sl No Project Description FY Responsible Agencies Project status

Interconnection of 4mT-7mTPA BF gas line interconnection for ensuring BF gas for gas mixing station at coke oven#3 even with BF#3 under down condition

2009-10

VP(EMD), Manager (Coke oven), Manager (EMD), Asst. Managers and technicians

Project has been completed

Replacing HP and high CV corex gas by LP and low CV BF gas for ore drying furnace of pellet plant. Utilizing mixed gas in corex gas network by regulating Corex gas pressure in case of one corex gas unit is under shutdown. Increasing the BF#3 Gas holder pressure from 1000mmWC to 1085mmWC for ensuring 100% operation of Gas mixing station.

2009-10

VP(EMD),Sr.Manager (EMD),Manager(EMD), Asst.Managers(EMD), Technicians VP(EMD),Sr.Manager (EMD),Manager(EMD), Asst.Managers(EMD), Technicians VP(EMD),Sr.Manager (EMD),Manager(EMD), Asst.Managers(EMD), Technicians

Project has been completed Project has been completed Project has been completed

2009-10

2009-10

Saving in Everything We Do

Sep-2010

11

Solid Waste Management 2009 - 10

Solid waste 2009-10 Quantity reused / recycled, t

Sl. No

Type of material

Waste used at

Generation , Tons

Equivalent of Energy

Coal & coke fines

Power plant, BFs, Coke ovens & sold

1558926

1585801

This is 31% of total energy for making crude steel

Iron making slag

Cement making, ground granulated BF slag BOF as coolant, IM, PP & SP as flux

1996666

1925638

This is 80% of total energy for making cement This is 25% of energy for making sinter This is 2% of total energy for making pellet Replacing iron ore

Steel making slag

1372837

254409

4 5 6

sludge dust Mill scale

Pellet plant Pellet plant & SP Base mix yard

199030 129744 58698

103462 21212 58698

Saving in Everything We Do

Sep-2010

12

Specific Water Consumption

Specific water consumption details (m3/Tcs) Year 2007-08 2008-09 2009-10 This has been achieved due to the following: 1.Waste water utilization at ore Beneficiation plant#2 2.Waste water also utilized for ore washing at BF#3 Consumption 3.13 2.93 2.18

Saving in Everything We Do

Sep-2010

13

Carbon Emission Reduction initiatives

Sales of Carbon credits

2008-09

2009-10

Variance

Percentag e

Rs.

49 crores

60 crores

11 crores

23%

This pertains to carbon credit earned against following projects: 1.By-product gas uses for power generation at captive power plant#1 2.Usage of Waste heat of non recovery coke plant for power generation at captive power plant#2

Saving in Everything We Do

Sep-2010

14

Future CDM Projects for Green Environment

Sl No Projects Total CO2 Reduction Tons of CO2/Yr Waste heat from B F Stoves Installation of Process boiler for utilizing 60,000Nm3/Hr of BF gas Utilization of BF Gas i.e. 100000 Nm3/hr for generating steam for power generation TRT for BF 4 2010 17975 Total annual Saving Rs. Investment Rs. Payback months 31

78.8

200

2011

290473

436.26

60

1.5

2011

484122

727.08

100 Part of total package 750

1.65

2011

149796

630

18

CDQ for 1.2 mTPA Non Recovery Coke Ovens

2011

89878

378

24

Saving in Everything We Do

Sep-2010

15

Renewable Energy at JSW

Traffic signals and Street Lighting at steel plant and Townships has been provided with Solar Energy. All the Guest houses have been provided with solar hot water facility. Jatropa cultivation has been initiated at Vidyanagar township and will be extended to around 75acres. The total energy generated is about 390000 units and a saving of Rs. 1033500. by solar photo voltaic Cells.

Saving in Everything We Do

Sep-2010

16

Environment projects-2009-10
3 new de-dusting systems at RMHS#2 (crusher building, screening building & proportioning building) to control the fugitive emissions. Tyre washing facility near beneficiation plant #1 to arrest the carry over of dust from the truck tyres on to the road. Installation of pneumatic conveying system at BF#1 dedusting system. This has resulted in reducing the downtime of the de-dusting system due to the problems encountered at the dust conveying arrangement. 5 de-dusting systems of Coke ovens Installed at the coal crusher house, coke screening & coke cutter house. 10 no. of stack monitors to monitor the dust level on a continuous basis. 3000 m3/hr. Compressor to cater to the new de-dusting systems & dry fog dust suppression systems

Saving in Everything We Do

Sep-2010

17

Environment projects-2009-10
AAQ at 3 stations to monitor PM 2.5, PM 10, TSP, SO2, Nox & CO on a continuous basis SGP at SMS1 to granulate the slag. DSS at RMHS junction houses & yards to control the fugitive emissions from yards & junction houses. Gas cooling at SP1 to control the temperature & hence reduce the damage to the electrodes. Pneumatic conveying at PP to utilize the bag filter dusts from various plant units.

Saving in Everything We Do

Sep-2010

18

ISO - NCRs for 2009-10( OCT09- Mar10)

To collect the dust generated during hot metal handling. Present Level: SPM 3763 microg/m3 Target : SPM 1500microg/m3. Objective :To collect the dust generated during blowing. Present level: SPM 4063 microg/m3 during blowing Target: SPM 1500 microg/m3 1. No action plan to implement the above evidenced. 2. SPM level not monitored since January 2009 to till date. 3. Since it is significant environment aspect auditee needs to take measures to control and bring it to the target level / norms as required by the applicable Environment act (EP Act 1986 amended in 1999).

Saving in Everything We Do

Sep-2010

19

ISO Corrective action 2009-10

Management to take the decision reg. Performance of Secondary De-dusting Systems for Mixer and Converter 2. EMD being central authority for monitoring dust levels help from EMD required to monitor the dust levels in these areas. Risk assessment of SP1- JB1C2 conveyor being reviewed and revised with immediate effect. Testing has been done but test report is awaited. As soon as the test certificate is recd. same will be submitted for inspection

Saving in Everything We Do

Sep-2010

20

10

ISO Preventive action 2009-10

As per the MOM of MRM No.36 dt.23/07/09, a circular has been issued to ensure usage of PPES in the work zone till the desired levels are achieved. The copy of the circular is attached. 2. EMD has agreed to continue monitoring the dust levels in these areas as it was done earlier. Henceforth, corrective and preventive action shall be taken after any incident after reviewing the risk assessment of the concerned activity. Test Certificates will be avl. in time. Follow up will be initiated with Safety Dept. so that test certificates are recd. in time.

Saving in Everything We Do

Sep-2010

21

Energy Based Innovative projects 2009-10

Installation and commissioning of BF gas network interconnection of 4mTPA and 7mTPA operating at varied operating pressure with control system: Net Saving: Rs 36.792Crores Replacement of high pressure and high CV corex gas by low pressure and low CV BF gas for ore drying at Pellet plant: Net saving: Rs 91.98crores Up gradation of BF gas holder pressure from 1000mmWC to 1075mmWC Net saving: Rs 168.192crores Utilizing 970mmWC mixed gas in 1000mmWC corex gas network during one Corex gas unit under Shutdown condition by controlling pressure in Corex gas network Net saving: Rs 50crores

Saving in Everything We Do

Sep-2010

22

11

Up gradation of BF gas holder pressure from 1000mmWC to 1075mmWC (Innovative project)

BF#3 gas holder was designed for a pressure of 1000mmWC Before commissioning of gas holder, BF gas network was operated with a pressure of 1150mmWC. It was experienced that, there was fluctuation of BF gas pressure in the upstream side of gas mixing station near Oxygen plant. Outlet of this mixing station was against Corex gas network pressure of 950 to 980mmWC. Due to fluctuation of upstream pressure 970 to 1000mmWC at Gas mixing station, mixed gas generation i.e BFG+COG was varying in between 30000Nm3/Hr to 40000Nm3/Hr. With 1000mmWC pressure of gasholder, there would be drop in pressure up to 10mmWC and it would not have been possible to generate mixed gas. Therefore, a proposal was made that gasholder pressure to be 1200mmWC. Accordingly a static load on piston was calculated and was found that, column foundation and structural cant take that much of load. Further, it was found that, pressure of 1075mmWC will be suitable as around 200Tons of weight on gas holder piston will be safe with existing foundation and columns.

Saving in Everything We Do

Sep-2010

23

Up gradation of BF gas holder pressure from 1000mmWC to 1075mmWC (Contd..)

But it was found that, there is not much area on top of the piston to accommodate concrete load of 200Tons. Therefore a decision was taken to use pig iron available at plant site. Hence pig iron were anchored by concrete. The pressure achieved was 1075mmWC. This has enabled us to generate mix gas up to 160000Nm3/Hr. Otherwise the gas was being flared. So there is gain of 125000Nm3/Hr of mixed gas. This has helped us also in generating mixed gas for largest HSM reheating furnaces. Overall mixed gas generation was possible up to 165000Nm3/Hr Cost of mixed gas Rs. 1.22/ Nm3 Cost of modification Rs. 25Lakhs Benefit works out to be 168crores/Anum

This work is one of its kind in any steel plant. This has made the gas network viable and for generating desired quantity of mixed gas for stable operation of plant.

Saving in Everything We Do

Sep-2010

24

12

BF-3 Gasholder (Innovative project)

Gasholder Dome

Designed Pressure -1000 mmWC Pressure Increased by Adding Pig Iron -1075 mmWC Piston Dome Pig Iron added to increase the weight of Piston Concrete Blocks Concrete Rubber Seal Shell Piston Rest Blocks

Saving in Everything We Do

Sep-2010

25

Energy Conservation projects 2010-2011

A
Sl No

Project Description Installation of 2 No.s of BF gas fired boilers for process Steam Interconnection O2 and N2 header of all Oxygen plant for flexibility of operation so as to operate all units Replacement of HP Corex gas by BF gas for 2nd Ore drying furnace of pellet plant Up gradation of EMC SCADA BF gas to power plant for power generation

Investment

Effect on Sp.Energy in Gcal/Tcs 0.064

Rs.600 Million

Rs 50 Million

0.05

Rs. 8 Million

0.0128

4 5

Rs 8 Million Rs 8 Million Total

0.02 0.1 0.2468

Saving in Everything We Do

Sep-2010

26

13

Energy Conservation measures 2010-2011

B
Sl No 1 Project Description Increasing BF Coal rate from 66. 23 to 100kg/THM Reduction of BF coke rate from 518 to 480kg/THM 2 Increasing the utilization of Corex gas from 97.94 to 98.94% Increasing TRT power generation from 3MWh to 8MWh Total Effect on Sp.Energy in Gcal/Tcs

0.0682

0.012

0.02 0.1002

Total Effect on Sp.Energy Consumption = A+B = 0.347Gcal/Tcs

Saving in Everything We Do

Sep-2010

27

Best Practices Observed On Energy Front

Preparing Energy budget with regard to by- product gas yield, Gas CV, Heat rate, Power rate, Utility utilization in shops. Budget as per experience and Energy improvement projects Energy Management through SCADA. Delay strategy followed by shops during short and long shutdowns. Low cost, No cost solutions for energy related problems. Planning and implementation projects under Capex. of Energy conservation

Continuous work for Energy security.

Saving in Everything We Do

Sep-2010

28

14

Energy Security Efforts at JSW

Optimizing the PCI (Pulverized Coal Injection) to reduce costly coke in all Blast furnaces Utilizing more than 15% non coking coal in coke ovens Corex gas utilization is > 98.4% Efforts are on for BF gas utilization > 95% by 2012 Has Installed TRT @ BF#3 i.e. for High Top pressure blast furnace About to install CDQ for recovery type coke ovens and produce 50MWh power generation JSW Steel is set to get Natural gas, another important measure for Energy Security

Saving in Everything We Do

Sep-2010

29

Energy Report
Energy Management Department Daily Plant Energy MIS Production Shops Unit On Date Till date Parameter CO 1&2 Gross Coke % No of pushing Nos Coke oven 1&2 2409 67348 Waste heat power Mwh Power Rate Kwh/tp CO3 Gross Coke % Specific heat Gcal/Tdc CO 3 gas yield Nm3/tdc Coke oven 3 4265 116572 Tar yield % of tdc No of pushings Nos Power Rate Kwh/tp Gaseous Heat rate Gcal/T Sinter Plant 1 6469 184574 Coke Breeze Heat Gcal/T Power Rate KWh/T Gaseous Heat rate Gcal/T Sinter Plant 2 7838 207757 Coke Breeze Heat Gcal/T Power Rate Kwh/T Gaseous Fuel rate Gcal/T Pellet Plant 10600 293540 Power Rate KWh/T For June 28, 2010

Target 74 112 64 12 74 0.65 310 3.2 224 55 0.007 40 0.007 40 0.12 70

On Date 70.8 108 55.6 16.42 72.4 0.61 332 2.85 221 57 0.007 0.388 42 0.006 0.194 38 0.13 65

Till date 71.2 108 53.5 16.51 72.5 0.61 315 2.91 216.5 57 0.007 0.402 39 0.006 0.150 39 0.131 67
30

Saving in Everything We Do

Sep-2010

15

Energy Report
Energy Management Department Daily Plant Energy MIS Production On Date Till date Parameter Coal Rate Crx 1 Coke Rate Crx 1 Corex 1 2207 55246 Oxygen Rate Crx 1 Nitrogen Rate Crx-1 Gas yield Crx 1 Coal Rate Crx 2 Coke Rate Crx 2 Oxygen Rate Crx 2 Corex 2 2003 56535 Nitrogen Rate Crx 2 Gas yield Crx 2 Corex gas C V Power Rate Coke Rate BF 1 CDI Rate BF 1 Gas yield BF 1 Blast Furnace 1 2841 74352 Oxygen Rate BF 1 Nitrogen Rate BF 1 Heat rate (stoves) Coke Rate BF 2 CDI Rate BF 2 Gas yield BF 2 Blast Furnace 2 3609 86029 Oxygen Rate BF 2 Nitrogen Rate BF 2 Heat rate (stoves) Power Rate Shops Unit Kg/Thm Kg/Thm Nm3/Thm Nm3/Thm Nm3/Thm Kg/Thm Kg/Thm Nm3/Thm Nm3/Thm Nm3/Thm Kcal/Nm3 KWh/Thm Kg/Thm Kg/Thm Nm3/Thm Nm3/Thm Nm3/Thm Gcal/Thm Kg/Thm Kg/Thm Nm3/Thm Nm3/Thm Nm3/Thm Gcal/Thm KWh/Thm Target 815 170 560 125 1680 815 170 560 110 1680 1855 85 520 80 1750 70/100 50 0.63 520 120 1885 55 50 0.50 50 On Date 900 185 615 144 1,638 963 159 630 122 1,812 1,870 109 452 100 1,609 48 48 0.45 469 100 1,793 55 65 0.59 48.8 Till date 867 199 744 288 1,817 899 191 615 118 1,798 1,898 113 466 90 1,675 46 46 0.44 452 77 1,930 45 83 0.60 53.55
31

For June 28, 2010

Saving in Everything We Do

Sep-2010

Energy Report
Energy Management Department Daily Plant Energy MIS Shops Production On Date Till date Parameter Coke Rate BF 3 CDI Rate BF 3 Gas yield BF 3 Oxygen Rate BF 3 8273 192424 BF 3 Nitrogen Rate B F 3 Power rate Heat rate (stoves) B F gas C V Heat rate 1875 46786 Power rate Oxygen rate Nitrogen rate 10238 259675 Power Rate Hot Metal rate LD Gas Recovery Argon Rate 10153 256235 Power Rate Oxygen rate Nitrogen rate 7140 177882 Power Rate Hot Metal rate LD Gas Recovery Argon Rate 7049 174687 Power Rate Heat rate 9903 227290 Power Rate Unit Kg/Thm Kg/Thm Nm3/Thm Nm3/Thm Nm3/Thm KWh/Thm Gcal/Thm Kcal/Nm3 Gcal/Ton KWh/Ton Nm3/Tls Nm3/Tls KWh/Tls Ton /Ton Nm3/Tls Nm3/TSla KWh/TSla Nm3/Tls Nm3/Tls KWh/Tls Ton /Ton Nm3/Tls Nm3/TSla KWh/TSla Gcal/Tp KWh/Tp Target 525 150 1800 50 50 160 0.50 750 0.75 34 54 28 45 1.027 100 2.00 18 54 28 45 1.027 100 2.00 18 0.27 90 On Date 437 105 1,601 90 36 147 0.49 750 0.75 37 57 50 42 0.996 113 1.20 18 59 45 70 1.216 0 1.82 30.6 0.279 80 Till date 450 87 1,782 84.87 58 160 0.53 750 0.79 35 59 46 43 1.024 107 1.39 19 59 39 69 1.235 0.00 2.15 30.0 0.368 88 For June 28, 2010

Blast Furnace 3

LCP

SMS 1

CCP 1

SMS 2

CCP 2 HSM-1

Saving in Everything We Do

Sep-2010

32

16

Energy Report
Energy Management Department Daily Plant Energy MIS Production Unit Target On Date Till date On Date Till date Parameter Heat rate Gcal/Tp 0.27 0.863 0.402 HSM-2 728 79444 Power Rate KWh/Tp 90 419 190 Heat rate Gcal/Tp 0.35 0.31 0.372 WRM 1702 29025 Power Rate KWh/Tp 160 156 212 Heat rate Gcal/Tp 0.4 0.29 0.552 BRM 2094 29892 Power Rate KWh/Tp 110 109 175 Heat rate Gcal/Tp 0.90 0.165 CRM CPL 0.298 380 66113 Power Rate KWh/Tp 95 613 129 CRM CCM BF gas consumption Nm3/hr 103,908 94,669 165000 Corex Gas Cons Nm3/Hr 98,513 96,305 CPP-1 104 2796 85000 Total Generation MWh 104 99 100 Corex Gas Cons Nm3/Hr 19,410 21,454 25000 BF gas consumption Nm3/Hr 136,333 120,111 CPP-2 111 2976 175000 Total Generation MWh 111 107 120 Plant load MWh 291 285 360 Electricity Specific power KWH/Tcs 406 447 560 SMS #1 CRM Total/day Iron 4 mTPA BF # 3 SMS # 2 HSM-1 3.90 0.05 3.80 3.90 0.52 0.39 LPG WRM & Others JPOCL BOC # 1 & 2 14.87 0.20 1.91 0.20 CO Gas 0.11 BF 1 & 16.62 BF 3 Gas 15.56 Corex gas 1.65 Losses (%) 6.67 (with BP norm) On date 6.34 Till Date 6.50 Specific Energy Consumption Remarks: 1)Good Hot metal rate in SMS -1 i.e 0.996 Thm/Tls. 2) Good Coke rate in Blast Furnace -1, 2 & 3. 3) Good CDI rate of Blast Furnace -1 i.e 100 Kg/Thm. Shops For June 28, 2010

Saving in Everything We Do

Sep-2010

33

ENERGY A Major Thrust at JSW

JSW Steel Since inception has taken care of Energy Efficient technologies

JSW Steel Cares for Energy

Daily Energy Review during ED(O) & HODs Meeting Energy is reviewed during weekly cost meeting SEC is the Key Result Area for Senior and Top Management CEO Reviews Energy during weekly production performance meeting CEO Reviews Energy during monthly production meeting MD Reviews performance of Energy conservation activities, future plans and encourages team for achieving set goals.

Saving in Everything We Do

Sep-2010

34

17

Saving in Everything We Do

Sep-2010

35

18