RASHTRIYA ISPAT NIGAM LIMITED

WIRE ROD MILL-2

Presentation on DET Activities & Energy Conservation Initiatives in WRM2

Department

DET MEMBERS of WRM-2:

KV Dinakar (HOD) – WRM2
Abidulla.Baig – GM (Mech)
N.Narayana Rao - DGM (O)
M.Yugandhar – DGM(Mech)
S.Bhattacharya – GM(E)
Tapan Kumar – DGM(O)
S.Mishra – DGM (Mech)
S.Bhanumurthy – DGM (E)
 WRM-2 PROCESS FLOW DIAGRAM Wire Rod
Mill-2

Process Chart

Pre
N Twist
Mill
NTM -A

Intermed
Roughing iate
Furnace
Mill
Mill-1 &
2

Pre REDUCING
No Twist
Finishing & SIZING
Mill
Mill MILL
NTM -B
PFM-B
RSM-B
 INTRODUCTION
• Rolling is a process in which input metal which is
preheated in a furnace above recrystallisation
temperature is passed through pairs of rolls to reduce to
uniform desired thickness and to impart a desired
mechanical property.

• Major sources of energy being consumed in this process

accounts to Energy consumed by the Reheating Furnace
and Electrical Energy consumed by Drives during the
rolling process
ENMS Objectives FY23-24

To Restrict Specific heat consumtion

< 242 Mcal / Ton of billet rolled.

To Restrict Specific Power consumtion

< 178 Kwh / Ton of billet rolled
 Previous Trend Analysis
Previous Trend Analysis
600
559.265
506.805
500

430.477
400

300
247 261 254
200 195
200 179.32

100

0
2020-21 2021-22 2022-23

SPECIFIC POWER (KWH/TBR) SPECIFIC HEAT (MCAL/TBR) PRODUCTION Tonnes(*1000)

 FY 2023-24 Target & Actual (Till OCT-23)
Target & Actual FY 2023-24
700
650
600

500

400
355.11
300
242 254
200 186.68 178

100

0
SPECIFIC POWER SPECIFIC HEAT PRODUCTION
(KWH/TBR) (MCAL/TBR) Tonnes(*1000)

TARGET (FY 2023-24) ACTUAL (Till Oct-23)

 DET ACTIVITIES
• Analyze deviations of EnPI from the target and justifying the same

• To conduct mandatory energy audit accredited to East coast sustainable

PVT.Ltd

• Bringing Energy awareness among employees by imparting training to one

third of employees every year

• Monitoring differential pressure in air recuperator

along with EMD whether within OEM limits

• Data collection of relevant variables Like Energy meters,power

factor, KVA , O2 Content in Flue gas, Idle Running ,Input Billet
Temparature
 DET ACTIVITIES
• Review and assessment of risk factors and make a comparative state
ment which includes external and internal Factors

• Conducting motor load survey of process motors rating greater than

90KW

• ASO Energy Meter verification for every 5 years

• Encouraging employees for energy saving suggestions and QC’S

• Complying internal/external Audit recommendations and

observations

• Online Compliance Entry by Department

ENERGY CONSERVATION
INITIATIVES OF WRM – 2
FOR 2022-2023
 Action Plans
To reduce Specific Heat

• Monitoring Hot Charging of Billets into the furnace through an additional pyrometer at furnace
entry

• Idle time of Furnace is being monitored during no rolling , controlling the Heat Demand using
level-2

To reduce Specific Power

• Idle running of Drives are monitored

• Compactor Idle running of pumps is reduced by incorporating in PLC Logic if equipment

is idle for more than 20 min.

• Auto switch off of 20 no’s of Blowers of 300 kw each when the rolling stops

• Replacing of HPSV and Flourescent Fittings with LED Fittings in a phased manner

• 8 mm Rebar Rolling done Without RSM

Action Plans To Reduce Specific Power
SCOPE FOR IMPROVEMENT :

1. LIGHTING (0.35 MW)

2. PUMPS & MOTORS (0.5 MW)

3. VFD DRIVES Idle Running (5.92 MW)

4. 8mm Rebar Rolling without RSM

 1.LIGHTING
Existing/Commissioned Lighting System Details

Lighting System:
Total connected load = 356 kw
Energy consumption per day (13 Hr on) = 4628 kwh
Annual energy consumption = 1689220 kwh
 1.LIGHTING
DET ACTIVITY:Connected Load reduction by LED Fittings and Auto
Control through PLC
Savings Achieved Future Scope
Load Saving Future Savings
Description QTY (KW) Description QTY (Lakhs)

CFL TUBE LIGHTS 36W

replaced by LED 18W 650 11.7 CFL Tube Lights 36W 946 4.36L

SODIUM VAPOUR LAMPS

70W replaced by 35W LED 100 3.5 SODIUM VAPOUR 70W 555 4.97L

SODIUM VAPOUR LAMPS SODIUM VAPOUR

400W replaced by 250W LED 50 12.5 400W 75 7.68L

SODIUM VAPOUR LAMPS SODIUM VAPOUR

800W replaced by 400W LED 20 8 150W 344 6.6L
Future Cost Saving
Total Load Savings 35.7 Scope 23.6 L

Load Reduced 35.7

Avg. Lighting On
Duration/Day 13 hrs
Annual Energy Saving 365*13*35.7 =169396 kwh

Cost Saving (Avg Rs 5.4 /

KWH) 9.11 Lakhs
 2.Pumps and motors
DET Activity Details
• In WRM-2 we have three compactors in the finishing area. these compactors
are used to bind the coil with strap by pressing the coil against two plates
under pressure created by hydraulic system and binding with strap using 4
strap head units.
• The hydraulic system comprises of 4 main pump motors and 2 circulation
pump motors, of these 1 main pump and 1 circulation pump are Standby.
• The motors data in hydraulic cellar per compactor is as follows:
55 KW -3 no’s
• During idle operation of compactors the pumps will be running and power is
getting wasted with out any utilization.
• The average load consumed by each motor is 35kw
• Total average idle running time is monitored and observed to be 1.5hrs/day
• A logic with interlocks is incorporated in the PLC such that when the
equipment is off for more than 20 min , the main pump motors were
commanded switched off .
 Energy Savings Achieved
EXISITING After Innovation

Description Power (KW) Savings Achieved Energy KWh

Max Power Consumed by
Compactors each(55W) 55*9=495
Saving after reducing
idle running (Avg 1.5 247.5*1.5*365=
With Avg Load Factor of 50 percent 495*0.5=247.5 Hrs/DAY) 135506

Costs Savings Achieved 135506*5.4= 7.3

(Avg Unit Cost Rs 5.4) Lakhs
 3.IDLE OPERATION OF DRIVES
DET Activity Details
• In WRM-2 we have 20 VVVF Drive controlled Blower Fans running during
High Carbon rolling of 315 KW Capacity

• Auto switch off of these Blower Fans is provided through PLC during Rolling
Interruptions of more than 10 min

• Idle running of Main Drives are monitored and Displayed to operator for
Awareness of Operators
Energy Savings Achieved
 4.8mm Rebar Rolling
DET Activity Details
• Earlier 8mm Rebar rolling was done through
RSM , By modifying pass designs and mill
configurations , we rolled 8mm Rebar through
NTM bypassing RSM which resulted in energy
savings
EXISITING (8mm Rebar with RSM ) Innovation (8mm Rebar without RSM )

Description Power (KW) Description Power (KW)

NTM Load 0.45 *5500 = 2475 NTM Load 0.57 *5500 = 3135

RSM Load 0.6 * 2800 = 1680 RSM Load 0

Total Load 4155 Total Load 3155

Power Savings Achieved = 1000 kw

Avg Rolling rate 125 Ton/hr
Energy Savings of 8KWH/TBR
Awareness to Operators
The following data is pasted in the pulpits
WRM2 POWER FOR DIFFERENT
SECTIONS AND GRADES .
SECTION GRADE POWER
1008 LC 19
HC 62 B 21.58
5.5
HC 68 B 21.53
HC 72 B 19.75
6.5 1008 LC 12.51
LC 22.68
HC 25.4
7.0
1008LC 21.62
1018 14.24
16
BORON 14.52
Impact on Specific heat & Power with
Critical Variables
S. No. Parameter Factor Specific Specific
Heat Power
(Mcal/TBR) (KWH/TBR)
1 Heat loss from Flue 1% 2.42 NA
Gas
2 Idle Running 1 Hour 15.2 22.3
3 Temp of Input Billet 100°rise 16.5 NA
4 Rolling rate 1 billet /Hr 0.2 0.177
5 Rolling Hours 1H rise/Day 1.2 1.68
6 Difference in HC and 16 Blowers NA 25
LC (Carbon) Rolling additional
Future Scope for Energy Saving
Department: WRM-2
Benefits
Parameters / Projects
(In term of Energy savings)
Considering reducing Billet to Billet gap of 3 s
4 Min Idle running is reduced per hour in 5.5 mm Rolling
per hour & 6 min in other than 5.5mm
Reducing Billet to Billet Gap by fine Tuning Auto Billet Average
Request Program and Optimising Cycle Times of Idle running of Drives Power Consumption : 5.92MW
Furnace Walking Beam ,Reform Tub and Compactors
and various Mechanical Equipments Saving of 493 Units / HR
Short term projects
Avg Unit Cost 5.4
Savings of Rs 2600 / hr

To replace all HPSV and Fourescent Lightings in a

23.6 Lakhs/Anually
phased manner

To optimize number of Blower fans running , without

To be coordinated with QATD and SMS
compromising on Quality
Medium Term Projects

To provide VVVF Drive for existing Conventional

To be discussed with OEM
Long term projects Combustion Air Fan subject to feasibiliity
One unit saved is two units produced
Monitoring of Air Recuperator Pressure
Drop

R
Air Recuperator Pressure Drop as per OEM

R
Risk Assessment

R
R
Motor Load Survey

R
Relevant variables

R
Data Collection of relavent Variables

R
Significant Deviations

R
Significant Deviations

R
Contribution of Variables to Specific Heat

Return
Contribution of Variables to Specific Power

Return
Furnace Efficiency as per OEM

Return
Energy Meters Verification

R
Energy Interpretation
Return
 Action Plans To Reduce Specific Heat
SCOPE OF IMPROVEMENT :

1. FURNACE

2. HOT CHARGING
ACTION PLAN FOR FUTURE
• While rolling of higher sections which have significantly
less rolling time compared to lower sections with high
rolling times , billet requests were generated in auto with
exisiting program causing delay between consequtive
bars increasing the idle time of the Drives

• Program to be developed and modified to reduce the gap

between the consecutive bars to less than 10 sec thereby
considerably reducing the idle time of Drives which
results in significant energy savings
Return