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WELCOMES

YOU

RECEIVING STATE ENERGY CONSERVATION AWARD ON BEHALF OF SMC

POWER GENERATION LTD. FROM PRINCIPAL CHIEF ENGINEER CUM CHIEF

ELECTRICAL INSPECTOR(SDA),GOVT. ODISHA

ODISHA STATE

ENERGY CONSERVATION AWARD

STATE ENERGY CONSERVATION AWARD OWNED BY SMC POWER

GENERATION LTD., ON NATIONAL ENERGY CONSERVATION DAY

2015

AWARD

Brief Introduction

SMC group was established by Late Shri Sewa Ramji, a well

respected entrepreneur from Saharanpur, Uttar Pradesh, India

in the year 1982 when he started a Paper Mill. The group

entered in steel sector in the year 1988.

In the year 2003 SMC Power Generation Limited was started an

integrated steel plant in village Hirma in the district of

Jharsuguda, Odisha with capacities of Sponge Iron 200000

MTPA, Billet 250000 MTPA, Rolling Mill 180000MTPA & Power

33MW. The Company is well-known for its quality steel product in

the brand name 'SMC THERMEX 500 QST.

Plant Profile

The unit wise installed capacity with the year of commissioning is

furnished below.

Particulars Unit Capacity Year of Commissioning

Captive Power Plant MW 8 2004

MW 25 2007

DRI-Kiln-1 TPA 100000 2004

DRI-Kiln-2 TPA 100000 2007

Steel Melting Shop TPA 250000 2007

Rolling Mill TPA 100000 2007

Rolling Mill TPA 80000 2013

PLANT PROCESS FLOW DIAGRAM

AFBC

WHRB-2

SMS ROLLING

MILL BILLETS

TG25

TG 8

IRON ORE

CRUSHER

COAL

CRUSHING

UNIT

KILN SPONGE IRON

WHRB-1

GRID

SMCPGL is comprised of Captive Power Plant. The requirement

of electricity for processes is primarily met from CPP (1x25 MW)

& (1x8 MW) with both coal based and Waste Heat Recovery type

generation.

The MRSS of SMCPGL is connected to the Kuchinda state grid

for import/export based on exchange of power.

The major energy sources of the plant are coal, LDO, HSD, HFO

and Electricity.

ENERGY & UTILITY SCENARIO OF THE PLANT

STATEMENT OF SPECIFIC ENERGY CONSUMPTION PUBLISHED

BY MINISTRY OF POWER, GOVT. OF INDIA.

Name, Address

and State

Specific energy

consumption

(TOE/T of

product) in base

line year

Product

Output

(Ton)

Specific energy

consumption

(TOE/T of

product) in target

year

SMC Power

Generation Ltd.

Hirma, Jharsuguda

Odisha

0.539 105094

0.512

PRODUCTION STATUS DURING THE YEAR 2012-13

PRODUCTION STATUS DURING THE YEAR 2013-14

PRODUCTION

0.00

20000.00

40000.00

60000.00

80000.00

100000.00

120000.00

140000.00

160000.00

180000.00

200000.00

base line year FY 2012-13

Total EnergyConsumption of PlantAnnual TOE

Total EquivalentProductSI+SMS+OthersAnnual Tonne

COMPARISION OF TOTAL ENERGY CONSUMPTION VS.PRODUCTION

IN BASE LINE YEAR 2012-13

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

base line year FY 2012-13

specific energy consumption

base line year

FY 2012-13

COMPARISION OF SPECIFIC ENERGY CONSUMPTION

IN BASE LINE YEAR 2012-13

0.00

20000.00

40000.00

60000.00

80000.00

100000.00

120000.00

140000.00

160000.00

180000.00

200000.00

FY 2012-13 FY 2013-14


Total EquivalentProductSI+SMS+Others AnnualTonne

COMPARISION OF TOTAL ENERGY CONSUMPTION IN

THE YEAR 2012-13 & 2013-14

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

FY 2012-13 FY 2013-14


FY 2012-13

FY 2013-14

COMPARISION OF SEC FOR THE YEAR 2012-13 & 2013-14

0.00

20000.00

40000.00

60000.00

80000.00

100000.00

120000.00

140000.00

160000.00

180000.00

200000.00

FY 2013-14 FY 2014-15


Total Equivalent ProductSI+SMS+Others AnnualTonne

COMPARISION OF TOTAL ENERGY CONSUMPTION IN

THE YEAR 2013-14 & 2014-15

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

FY 2013-14 FY 2014-15


FY 2013-14

FY 2014-15

COMPARISION OF SEC FOR THE YEAR 2013-14 & 2014-15

To reduce the specific energy consumption after the base line year we had

taken several encon projects like installation of VFD’s in our major energy

consuming equipment's such as

a) Installed VVFD in PA fan of AFBC boiler.

b) Installed VVFD in CWP motor of our 8MW TG set.

c) Installed hot billet conveyor belt system from SMS to Rolling Mill to carry

out the hot billet directly from SMS to rolling Mill for TMT production. This

could save a huge amount of thermal energy as the reheating of billets

could be avoided.

The detailed project cost and saving achieved are as under.

d) In place FO we use biomass firewood for laddle heating.

The major saving we record from the hot billet conveyor system as shown below

STEPS TOWARDS ENERGY SAVINGS


ROLLING MILL

Online Hot Billet Charging through High Speed Conveyor

• Hot Billet Shearing machine taken in PLC Automation

• Online Temperature Monitoring Pyrometer


ROLLING MILL

• Installed HMI PLC automation for Hot

billet shifter to reduce reject of Billets


ROLLING MILL

• Installed Hot Billet

counter

• Installed Water flow

meter for accurate

water measurement

in Rolling Mill


STEEL MELTING SHOP

TDU IMPLEMENTED

• Installed True Demand Utilizer

for Load Sharing & controlled

• Export / Import


SPONGE IRON DIVISION

Implemented AC Drives for CB / ABC / Shell-air fans & Lobe Compressors

• Maximum Power Consumption Save & Productivity increases

• Maintain Operation measures

• Fuel Oil consumption reduces from 5800 litres to 4500 litres (Light-up)

• Specific Coal consumption reduces fro 0.50 % up to 0.46 % C/Fe

• Coal Consumption reduces from 1.7 ton to 1.2 ton

• Steam generation increases up-to 25 ton/Hr to 28 ton/Hr

• Unit Per Ton achievement from 77-80 tons to 58-65 tons(High Production)

Sl.

No.

Details of energy

efficiency

improvement

measure

Investment

in Rs.

Verified

Savings in

Rs

Verified

savings

Energy

Units Fuel Remarks Completion

Date

1 VFD INSTALLED

IN PA FAN AFBC 3,00,000 6,26,340 120 MWh/Yr.

10.36

TOE/Yr.

2

HOT BILLET

CONVEYOR BELT

SYSTEM

ADOPTED FOR

ROLLING MILL.

61,24,350 109141898.5 9123.334 MWh/Yr 5.33

TOE/Yr.

REHEATING

OF BILLETS

NOT

REQUIRED

FOR

ROLLING

MILL

FY 2013-14

3

COOLING WATER

PUMP MOTOR-

1(250KW)

4,00,000 14,23,500 274 MWh/Yr. 23.54

TOE/Yr.

Some of our energy saving measures that we have

taken in the recent past to reduce SEC

Sl. No. Details of energy efficiency

improvement measure

Investment -

(Rs. Estimated)

Verified Savings

(Rs. Estimated)

Verified savings -

Energy Savings

Estimated

Units Fuel

1 COMPRESSOR-1(SID) 2,00,000 4,27,050 82 MWh/Yr. 7.06MTOE/Yr.








9 COOLING WATER PUMP 2 (250KW)

LT MOTOR 4,00,000 14,23,500 274 MWh/Yr. 23.54MTOE/Yr.

10 COOLING WATER PUMP 3(250KW)

LT MOTOR 4,00,000 14,23,500 274 MWh/Yr. 23.54MTOE/Yr.

11 BOILER FEED PUMP-1(180KW) LT

MOTOR 3,70,000 10,24,920 197 MWh/Yr. 16.95MTOE/Yr.





14 CONDESATE EXTRACTION PUMP-

1(55KW) LT MOTOR 1,75,000 3,13,170 60 MWh/Yr. 5.18MTOE/Yr.

15 CONDESATE EXTRACTION PUMP-

1(55KW) LT MOTOR 1,75,000 3,13,170 60 MWh/Yr. 5.18MTOE/Yr.

ENERGY CONSERVATION PROJECTS UNDER IMPLEMENTATION

Sl. No. Details of energy efficiency improvement measure

1 LOBE COMPRESSOR-1(110KW) LT MOTOR


3 PSB ID FAN(110KW) LT MOTOR

4 CB FAN-1(45KW) LT MOTOR

5 CB FAN-2(45KW) LT MOTOR

6 COOLER MAIN DRIVE-1(150KW) LT MOTOR

7 COOLER MAIN DRIVE-2(150KW) LT MOTOR


9 TRANSPARENT ROOF SHEET TO BE INSTALLED IN DG ROOM, TG BUILDING, COMPRESSOR

HOUSE FOR EFFICIENT USE OF DAY LIGHT

10 ASTRONOMICAL TIMER SWITCH TO BE INSTALLED FOR STREET LIGHTING SYSTEM.

11 LED LIGHTS ARE TO BE USED FOR OFFICE LIGHTING.

12 CAPACITOR BANK 500KVAR AUX.PANEL-1

13 CAPACITOR BANK 500KVAR AUX.PANEL-2

Our dedicated team of energy cell is continuously doing efforts for save every single unit of

energy & we have some more Energy saving projects to be implemented in the upcoming year.

ENERGY SAVING MEASURES TO BE IMPLEMENTED

We have constructed 4 no. of reservoir for rain water harvesting.

Reservoir-3

Reservoir-1 Reservoir-2

Reservoir-4

The water generated from the domestic source is collected in the Sewage pond /

Settling pond by connecting all the drainage system of the plant to the settling

pond. Since the settling pond is some water at lower level than plant site the

waste water getting collected easily without pumping. which we are using for road

sprinkling and in other purposes like conditioning of ash etc. later on.

SAVE ENERGY

SAVE NATION

SAVE WORLD

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