We are pleased to announce that we have started conducting energy audit of steel plants. Our energy audit includes various systems of the steel plants ie electrical systems, water systems, air compressors & lighting systems etc. This section will give you detailed scope of work, expected output of the audit and other aspects pertaining to the energy audit.

A.   Scope of Work:

1. Electrical Distribution Network & Usage:

• Metering and Monitoring Status: Review of existing energy meters for adequate monitoring requirements. Feasibility study for continuous energy monitoring
• Electricity Bills: Study of present consumption pattern and recommendations for optimisation of electricity bill parameters.
• Logging of all electrical parameters at main incomer
• Thermal imaging of all major incomers, capacitor panels and other loads in the panel rooms for safety & energy saving opportunity.

2. Electrical Loads of rolling machines:

• Measurement of all major electrical parameters viz. voltage, current, power(kwh), power factor, frequency etc. of major motors used in the section
• Logging of electrical parameters over a period of time for hydraulic power packs for determining their operational loads
• Proper evaluation of kWh / ton production and comparison with industrial benchmarks for optimization
• Recommendations for enhancing performance/ replacement/ retrofit of present systems
• Recommendations for optimal usage of machines to avoid idle time operation and proper use of utilities
• Thermal Imaging of total machine motors
• Checking the health of motor in-case of rewinded motor

3. AIR COMPRESSORS AND COMPRESSED AIR SYSTEM

• To observe the present status of compressors and distribution piping, note points of leakage wherever possible and assess compressed air wastage.
• Study compressed air applications to optimize air usage and pressure for applications.
• To broadly study the existing air distribution piping and estimate pressure losses in the present compressed air system.
• To work out operating performance of compressors.
• Direct instantaneous measurement of kW consumed by motors driving the compressors. Logging over a period of time to determine unloading / loading & VFD operations.
• Based on the above study and analysis, work out suggestions for improvement, this will result in energy conservation. The suggestions will cover the following area :
  • Improvement in efficiency of compressed air generation
  • Reduction in leakage / losses
  • Improvements in the distribution system

4. Water System / Cooling Towers :

• Measurement of operating efficiencies of major water pumps including cooling water pumps etc. Measurement of flow, head and power so as to determine this operating efficiency
• Study the performance of cooling towers in terms of range and effectiveness and recommendations for optimization
• Study the cooling loads catered by the cooling towers and optimization of the same

5. Other Loads in the plant:

• Study of blowers and recommendations for optimization
• Study of lighting loads and recommendations for optimization
• Study of other miscellaneous loads for optimization

B.      Expected output of the audit

The results of the audit will be submitted in the form of a report containing:

• Energy profile with percentage share of major equipment, utilities etc., so that it becomes a basic document for future monitoring.
• Energy saving proposals with little or no investment. These will include operational changes, minor modifications and retrofits.
• Investment proposals (involving more efficient equipment/processes) with payback period calculations for energy conservation in the systems audited.
• Analysis of data from the logbooks and that taken from field measurements with the help of portable energy audit instruments provided by us.

ANT has developed in-house the software for roll pass design. With the help of software, database and practical experience ANT help their customers to develop new profiles in their mills.

ANT is also specialized in the rolling of alloy steel in various sizes and sections.

We, at ANT Steel Engineers (Asia) Pvt. Ltd., provide following services to existing/ongoing steel plants:

• Expansion of existing facility
• Layout modifications
• Technology modernisation
• Additional equipment specifications
• Increase in productivity by optimum utilisation of resources
• Improvement in casting technology
• Increasing the casting speed of CCM and planning long sequences
• Updating Standard Operating Practices (SOP)
• Slag disposal techniques
• Development of alloy steel through induction furnace route
• Overall cost reduction by optimizing consumption of all inputs
• Energy audit
• Turnaround of sick unit
• Technical audit

At present we have plenty of satisfied customers under this category who have been enhanced their capability with our engineering services.

We, at ANT Steel Engineers (Asia) Pvt. Ltd., do green field projects from concept to process stabilization.

For green field projects, our scope for professional services includes:-

• Finalizing the project concept
• Development of mill layout
• Equipment specifications (inquiry documents) of main mechanical and electrical equipment
• Equipment specifications (inquiry documents) for auxiliary systems like material handling system, water circulation system, lubrication system, pneumatic system, hydraulic system, power distribution system

• Building specifications and design
• Detail engineering for civil foundations for mill equipment, column footing design, electrical rooms, scale pits, sedimentation tanks, cooling towers and  cable tranches
• Design of
  • Electrical control rooms
  • Water treatment plants
  • Cable scheduling
  • Process description for automation
  • Piping layouts, P & I diagrams, Piping isometric drawing, BOQ
• Technical verification of offers for various equipment and systems.
• Inspection of equipment
• Preparation of organization chart
• Additional services
  • Preparation of SOPs,
  • Training on plant operations
  • Roll pass design
  • Project monitoring

Technical audits were conducted for the following plants:

1. Indore Iron and Steel, Indore, India
2. Steel Exchange India Limited, Vizag, India
3. Jaideep Steels Power Limited, Indore India
4. Tulsyan NEC Chennai, India
5. Mahalaxmi TMT, Wardha, India
6. Amreli Steel Karachi, Pakistan
7. Star International, Sharjah, U.A.E.
8. Madhvani Steels, Uganda

After the technical audit, bottle-neck of the plants were identified for necessary actions.

ANT is also in the business of functioning as Independent Engineers for Banks/Financial Institutions for independent verification of project parameters and project monitoring.

Presently, ANT has been engaged by a consortium of banks in Bangladesh for the upcoming steel melt shop project of one million tons per year capacity. ANT bagged this order under stiff global competition.

The wide ranging scope of this consultancy services encompassed starting from appraisal of Conceptual and Technical design of the project, Plant design, Technology adopted, Project implementation, Project schedule and Cost deviation, Evaluation of Erection and Performance tests.

The final report of phase-I is already submitted before the target date and well accepted by the 3 Banks. The assignment given to ANT for phase-II is in progress.

ANT prepares standard operating practices for steel plants. Many plants have improved their efficiency with the help of standard operating practices.

Some of the plants are:

• Madhav Alloys Pvt. Ltd., Mandi Gobindgarh
• Mahalaxmi TMT, Wardha
• Jaideep Ispat and Alloys Pvt. Ltd., Indore
• Hill Metals, Saudi Arabia
• Tulsyan NEC, Chennai
• Modern Steel (Rolling Mill), Oman
• Monnet Ispat & Energy Ltd., Raigarh
• M.K. Steel, Raipur