POWER MINING FERRO AGRI NAVA BHARAT National Award For Excellence in Energy Management - 2017 GO - GREEN
NBVL Global footprints Company profile NAVA BHARAT Kharagprasad (Odisha): Chromium Alloy Plant & Power Plant Dharmavaram (AP): Power Plant Samalkota (AP): Sugar India : Ferro Alloy, Power & Sugar , Corporate Office Plant & Power Plant Singapore : International Office Paloncha (Telangana): Laos : Development of hydro-electric power project Manganese Alloy Plant & Power Plant Zambia : Coal Mining & 300 MW Thermal Power Plant Hyderabad: Corporate Tanzania : Identifying opportunities for mining and setting up agri projects Office 2 GO - GREEN
Unit profile NAVA BHARAT Ferro Alloy Division Power Division (CPP) Smelters: 2 x 22.5 MVA Capacity: 30 MW + 60 MW Products: Ferro Chrome Type: Coal Based TPP Output Capacity: 75,000 TPA Fuel: Domestic Coal from MCL 3 GO - GREEN
Process Flow NAVA BHARAT Raw Water From Coal From Washeries Coal From Mines Brahmani River Coal Yard RW Pump House Economizer CHP Reservoir DRUM PSH Clarifier MWPH SSH Bunker Flue Gas APH ESP Cooling Tower DM Plant Bed Comp IBSH FLY ash Compressor Bed Ash house Pneumatic Ash conveying System UCFT STEAM TURBINE GEN SILO SILO HP HEATERS Condenser Deareator Dry ash to Brick plants Ash pond etc. through closed trucks LP HEATERS SWITCH YARD AUX LOAD 4 GO - GREEN
14 Years of excellence of NBVL-CPP NAVA BHARAT 2003 Commissioning of Unit - 1 ( 30 MW) CPP 2005 Implementing 5S concept at workplace 2008 Commissioning of Unit - 2 (60 MW ) CPP 2008 Commissioning of 175 TR capacity VAM NAVA BHARAT 2009 Certified with ISO 9001 and ISO 14001 2012 Certified with OHSAS 18001 and ISO 50001 2014 Commissioning of 100 m 3 /day green STP 5 GO - GREEN
Go-Green: The Way Forward NAVA BHARAT G reen house Gas Management and Mitigation GHG Mitigation O ptimizing Gate to Gate Energy performance Energy Effectiveness Greenbelt G reenbelt development and tree plantation Development Renewable R enewable energy and day lighting Utilization Energy GO - GREEN Water E xcellent Water Management system and ZLD Management Technology E nhancing efficiency by technology Absorption Absorption Waste N et Zero waste (Effective waste management) Management 6 GO - GREEN
GHG Management NAVA BHARAT Objectives of Green House Gas Management: Establishing the Baseline, based on 2013 - 14 activity data Reducing the Intensity of Green House Gas (GHG) Emissions Improving the Gate to Gate energy performance of the Unit Conserving the resources & Utilization of Renewable energy Technology Absorption, Reduce, Reuse and Recycling Waste Including Indirect green house gases in GHG Management Monitoring, Reviewing and real time data transmission of Indirect green house gases to PCB server through RT - DAS Tree Plantation and green belt development Creating Awareness among the employees 7 GO - GREEN
GHG Management NAVA BHARAT Managing Green House Gas (GHG) emissions : Nava Bharat Ventures Ltd, Dhenkanal, Orissa adopted Emission based calculation approach for calculating the Co 2 e and 2013-14 as a base line year Scope 1 emissions Scope 2 emissions Year CO 2 e (MT) CO 2 e (MT) Total Activity Fuel used in power generation CO 2 e (MT) Import Power Description and Startup oil consumption 2013 - 14 680562.03 3.97 680565.9 2014 - 15 589323.12 24.47 589347.6 2015 - 16 654254.37 11.16 654265.5 2016 - 17 613818.85 38.90 613857.7 Tonnes Global Carbon Dioxide Activity Emission of Warming Equivalent X = X = Data Factor Emission Potential (CO 2 e) of (t) (GWP) Emissions 8 GO - GREEN
GHG Management NAVA BHARAT : Scope-1 Emissions : Scope-2 Emissions 1.26 1.26 1.84 2.00 1.26 1.75 1.70 1.80 1.61 1.23 1.24 1.60 1.22 1.40 1.20 1.2 1.00 8.05 % 1.17 1.18 0.80 7.14 % 0.60 1.16 0.40 1.14 0.20 0.00 0.00 0.00 0.00 0.00 1.12 Baseline 2014-15 2015-16 2016-17 Baseline 2014-15 2015-16 2016-17 GtG Energy Consumption under Green House Gas Emissions Iron & Steel Sector (Toe / MT) Intensity (CO 2 e / MWh) Reduction Reduction 9 GO - GREEN
Energy Effectiveness at NBVL-CPP NAVA BHARAT Way of Energy Effectiveness: Ensuring quality of raw materials Proper blending of raw materials Ensuring 100 % equipment availability Procurement of energy efficient products Maintaining the power quality and Power Factor Energy conservation projects and management action plans Reducing the idle running of crushers, conveyors and other equipments Efficient operation of plants in accordance with the documented criteria Systematic approach with energy management system (ISO 50001 : 2011) 10 GO - GREEN
Energy conservation methodology NAVA BHARAT NBVL follows PDCA methodology : Identifying the Legal and Other Requirements Ensuring the Competency of People & creating awareness Conducting energy Review / Audit (Internal / External) Establishing and Communicating the Operational Criteria Identifying & prioritizing the Opportunities for Improvement for effective and efficient plant operation Establishing the Baseline, Identifying the EnPI Procurement of Energy Efficient Products Establishing the Objectives and Targets Maintaining The required Documents Establishing the Action Plans Monitoring the Key characteristics Ongoing Energy Review by functional chiefs Evaluation Of Legal Compliances EnMS Review by management representative Conducting regular Internal Audits Taking decisions for Energy performance improvement Identifying potential non conformities & taking C-CAPA Continual Improvement 11 GO - GREEN
Plant Heat rates NAVA BHARAT 3399 3399 3049.6 3049.6 3400 3060 3378 3040 3380 3020 3360 2985.7 3000 3340 2980 2.94 % 3320 2960 3299 2931.7 3.86 % 2940 3300 2920 3280 2900 3260 2880 3240 2860 Baseline 14-15 15-16 16-17 Baseline 14-15 15-16 16-17 90 MW CPP Net Heat Rate 90 MW CPP Gross Heat Rate (kCal / kWh) reduction (kCal / kWh) reduction 12 GO - GREEN
Specific energy consumption NAVA BHARAT 0.98 0.98 12 1.00 11.62 12 0.96 11.14 0.91 11 0.92 12.2 % 10.28 10.28 11 0.88 0.86 10 0.84 10 0.80 Baseline 14-15 15-16 16-17 Baseline 14-15 15-16 16-17 90 MW CPP % Auxiliary 90 MW Specific Coal Consumption Consumption (Kg / kWh) 13 GO - GREEN
Comparison with Competitors & National Benchmark NAVA BHARAT 3399 3400 2.94 % 3299 3300 3200 PAT Target 16-17 Comparison with nearest competitors and National Comparison of Net Heat Rate Benchmark with PAT Target Source of National Benchmark: From the data of 1 st and 2 nd prize winners of BEE National Energy Award 2014 -15 PAT Target: CPP PAT Target was derived from the combined GtG PAT target of NBVL-DKL under Iron & Steel sector 14 GO - GREEN
Roadmap to achieve benchmark NAVA BHARAT Utilizing the day light by Providing Double glazed transparent sheet Performance evaluation of Air Preheater and replacing the damaged tubes Upgrading the Plant lighting with LED lights Changing of bed ash conveying system operation to probe mode instead of timer mode Providing the VFD to one of the CEP in Unit-2 Application of Corrocoat coating to the internals of CWP-1 in Unit-2 15 GO - GREEN
Innovative project-1 Modification of ESP Hopper Heater area NAVA BHARAT Description of the Project : Implemented In In order to maintain the ESP hopper temperature the ESPs of Unit-2 2016-17 were provided with Hopper Heaters. As the installed area of ESP hopper heaters was exposed to atmosphere the heaters are Annual savings remaining in ON continuously. Hence the running hours was more 0.0098 MU and consuming more energy Investment (Rs.) Innovation: 0.0245 Million A study was conducted and to minimise the heat loss from the hopper heaters area it is decided to provide thermal insulation GHG Reduction around the heaters and the same is implemented 16.66 Co 2 e Providing Glass wool at ESP Hopper Heaters area ESP Hopper Heaters area with complete Insulation 16 GO - GREEN
Innovative project-2 Providing Sacrificing Sleeves In Air Preheater Tubes NAVA BHARAT Description of the Project : Implemented In For preheating combustion air, Air pre- heaters are used & due to 2014-15 velocity of the flue gas the APH tubes are eroding. This tube erosion leads to thinning & ultimately results in tube failure, reduces the Annual savings APH performance & over loads the ID fan. Repairing of eroded 0.343 MU tubes involves more time & require long Boiler down time Investment (Rs.) Innovation: 0.03 Million A study was conducted and APH entry and exit area pipes are identified as significant eroded areas and it is decided to provide GHG Reduction self sacrificing ferrules to avoid the erosion of parent tubes, the Sleeve 583.1 Co 2 e same is implemented APH tubes without sleeves APH tubes with sleeves 17 GO - GREEN
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