Energy Conservation

1. Monthly Review Panoli AUG-2022

2. ENERGY SCENARIO 2022-23
Month Production (MT)
Coal
Consumed
(MT)
Specific Steam
Generation (Steam
genration/kg of Coal)
(kg/kg)
Specific Steam
Consumption
(Steam
Consumption/kg
of Prod.) (kg/kg)
Specific Fuel
Consumption
(Fuel
Consumption/kg
of Prod.) (kg/kg)
Specific Nitrogen
(N2) Consumption
(N2 Consumption/kg
of Prod.) (kg/kg)
TARGET YTD 2022-23 4.88 1.74 0.37 0.104
Sep-22 1143.2 562.32 3.98 1.98 0.49 0.101
Aug-22 1282.4 629.12 4.06 1.99 0.49 0.105
Jul-22 1509.4 771.47 4.03 2.07 0.51 0.106
Jun-22 1513.6 824.44 3.6 1.98 0.54 0.113
May-22 1750.2 855.41 3.7 1.86 0.49 0.109
Apr-22 1545.3 674.29 3.8 1.77 0.44 0.114

3. SEQD C M
Specific Steam Consumption – KG/KG
Comments :
- Various Steam savings initiates
taken up at Curing for execution
- Minimize the application of TCP
as autoclave.
- Steam hose pipe supplier
changed and address the
quality issues.
- Avg wt. of tyre reduced from
58.8 to 52.8 kg
Month FY22-23 Apr-22 May-22 Jun-22 Jul-22 Aug-22 Sep-22 Oct-22 Nov-22 Dec-22 Jan-23 Feb-23 Mar-23
Actual 1.92 1.77 1.86 1.98 2.06 1.99 1.98
Target (22-23) 1.74 1.80 1.80 1.80 1.75 1.75 1.75 1.70 1.70 1.70 1.70 1.70 1.70
2.07
1.74
1.942
1.80 1.80 1.80 1.75 1.75 1.75 1.70 1.70 1.70 1.70 1.70 1.70
1.77
1.86
1.98
2.07 1.99 1.98
0.000
0.500
1.000
1.500
2.000
2.500
YTD
21-22
Target
-
YTD
Apr-22
May-22
Jun-22
Jul-22
Aug-22
Sep-22
Oct-22
Nov-22
Dec-22
Jan-23
Feb-23
Mar-23
YTD
22-23
YTD 22-23 SPC -FY2122 Target SPC -FY22/23

4. SEQD C M
Sp. Fuel Consumption (Coal to Prod ) – KG/KG
Comments :
- Skin temperature study done
on all headers and where
temperature reading out of
limit addressed.
- Increase in ratio due to
frequent failure in curing
steam traps. Corrections
taken & being monitored on
weekly basis.
- Trench #1 Trials for 4 days
- Condensate generation
increase due to rainy season.
Month FY22-23 Apr-22 May-22 Jun-22 Jul-22 Aug-22 Sep-22 Oct-22 Nov-22 Dec-22 Jan-23 Feb-23 Mar-23
Actual 0.50 0.44 0.49 0.54 0.51 0.490 0.49
Target (22-23) 0.37 0.45 0.42 0.42 0.39 0.39 0.37 0.36 0.36 0.34 0.34 0.32 0.32
0.36
0.49
0.40 0.40 0.40
0.37 0.37 0.37
0.34 0.34 0.34 0.32 0.32 0.32
0.44
0.49
0.54
0.51 0.49 0.49
0.000
0.100
0.200
0.300
0.400
0.500
0.600 Target
-
YTD
Apr-22
May-22
Jun-22
Jul-22
Aug-22
Sep-22
Oct-22
Nov-22
Dec-22
Jan-23
Feb-23
Mar-23
YTD
22-23
YTD 22-23 SPC -FY2122 Target SPC -FY22/23

5. SEQD C M
Specific Steam Generation (Steam to Coal ) – KG/KG
Comments :
- Coal handling plant put in
operation and avoiding using
crushed coal
- Reduce carpet and fins loss.
- Complete automation of Boiler.
- Reduce radiation loss by
covering all un-insulated
portion.
- NRV provided in 12 TPH Boiler
- Presently Boiler load is 25%
load. For better efficiency of
boiler to operate at 80-85%.
- GCV of coal to monitor for
boiler efficiency at 5500 ADB.
Month FY22-23 Apr-22 May-22 Jun-22 Jul-22 Aug-22 Sep-22 Oct-22 Nov-22 Dec-22 Jan-23 Feb-23 Mar-23
Actual 3.78 3.80 3.70 3.60 4.030 4.06 3.98
Target (22-23) 4.88 4.50 4.50 4.50 4.75 4.75 4.75 5.00 5.00 5.00 5.25 5.25 5.25
4.88
3.862
4.50 4.50 4.50
4.75 4.75 4.75
5.00 5.00 5.00
5.25 5.25 5.25
3.80 3.70 3.600
4.030 4.060 3.980
2.000
2.500
3.000
3.500
4.000
4.500
5.000
5.500
6.000
Target
-
YTD
Apr-22
May-22
Jun-22
Jul-22
Aug-22
Sep-22
Oct-22
Nov-22
Dec-22
Jan-23
Feb-23
Mar-23
YTD
22-23
YTD 22-23 Steam/coal SPC -FY2122 Target Steam/Coal SPC -FY22/23

6. SEQD C M
Nitrogen (N2) Consumption– KG/KG
Comments :
-Leakage checking in
every shift
-Focus on tanker
unloading time ( each
tanker 200 kg loss)
-Improved Internal hose
pipe quality.
Month FY22-23 Apr-22 May-22 Jun-22 Jul-22 Aug-22 Sep-22 Oct-22 Nov-22 Dec-22 Jan-23 Feb-23 Mar-23
Actual 0.111 0.114 0.109 0.113 0.106 0.105 0.101
Target (22-23) 0.104 0.108 0.108 0.108 0.108 0.103 0.103 0.103 0.103 0.100 0.100 0.100 0.100
0.110
0.104 0.108
0.108 0.108 0.108 0.108
0.103 0.103 0.103 0.103 0.103 0.100 0.100 0.100
0.114
0.109 0.113
0.106 0.105 0.101
0.000
0.020
0.040
0.060
0.080
0.100
0.120
0.140
YTD
21-22
Target
-
YTD
Apr-22
May-22
Jun-22
Jul-22
Aug-22
Sep-22
Oct-22
Nov-22
Dec-22
Jan-23
Feb-23
Mar-23
YTD
22-23
YTD 22-23 SPC -FY2122 Target SPC -FY22/23

7. SEQD C M
Water Consumption– Ltr./Kg
Comments :
-Leakage checking in
every shift
--GIDC main supply line
leakage month of April-
2022 ( water loss 3000kl
app)
-GIDC water line leakage
month of AUG-2022
(water loss 450KL)
Month FY22-23 Apr-22 May-22 Jun-22 Jul-22 Aug-22 Sep-22 Oct-22 Nov-22 Dec-22 Jan-23 Feb-23 Mar-23
Actual 4.25 6.53 4.42 3.94 2.63 3.72 2.50
Target (22-23) 3.63 4.00 4.00 4.00 3.75 3.75 3.75 3.50 3.50 3.50 3.25 3.25 3.25
3.63
3.960
4.00 4.00 4.00
3.75 3.75 3.75
3.50 3.50 3.50
3.25 3.25 3.25
6.53
4.42
3.94
2.63
3.73
2.50
0.000
1.000
2.000
3.000
4.000
5.000
6.000
7.000 Target
-
YTD
Apr-22
May-22
Jun-22
Jul-22
Aug-22
Sep-22
Oct-22
Nov-22
Dec-22
Jan-23
Feb-23
Mar-23
YTD
22-23
YTD 22-23 SPC -FY2122 Target SPC -FY22/23

8. 1
Maintain the Coal Consumption Pattern
Month
Production
(MT)
Steam
Generation [M3
]
Coal [MT]
Steam -
Production Ratio
[KG/Kg]
Fuel - Production
Ratio [Kg/Kg]
Apr. 2022 1545.18 2729.04 674.29 1.77 0.44
May. 2022 1749.84 3260.38 855.41 1.86 0.49
June. 2022 1512.37 2991.54 824.44 1.98 0.55
July. 2022 1509.52 3107.82 771.97 2.06 0.51
Aug. 2022 1282.40 2555.30 629.12 1.99 0.49
Sep-22 1143.24 2267.57 562.32 1.98 0.49
TARGET :- 700MT COAL @1500MT PRODUCTION

9. 1
ACTIVITY INITIATED FOR STEAM SAVING
Insulation Skin Temperature Report Main Steam Header
(Boiler to 4-Roll Calendar)
07.8.2022 10.9.2022
Sr.
No.
Location Temp.( 0
C ) Temp.( 0
C )
1 Main Line Boiler to Steam Distribution Header 34.3 33.0
2 Main Steam Distribution Header point -1 (In-let from Boiler to Header) 31.2 35.4
3 Main Steam Distribution Header point -2 (Out-let Header to PRS) 31.3 33.1
4 10" main header to PRS - before 1 st Expansion loop 30.5 38.5
5 10" main header to PRS - on 1 st Expansion loop 29.9 32.0
6 10" main header to PRS - before 2 nd Expansion loop 34.1 34.4
7 10" main header to PRS - on 2 nd Expansion loop 33.0 33.6
8 10" main header to PRS - before 3 rd Expansion loop 35.4 35.4
9 10" main header to PRS - on 3 rd Expansion loop 32.9 32.9
10 10" main header to PRS - before 4 th Expansion loop 38.5 32.4
11 10" main header to PRS - on 4 th Expansion loop 32.0 34.1
12 10" main header to PRS - in between 4 th Expansion loop & PRS 32.7 34.7
13 Inlet to PRS 27.3 35.2
14 H.P. steam line from PRS to Curing 27.3 32.7
15 M.P. steam line from PRS to Curing 26.8 31.9
16 HP Down-comer line (Trench-3) 32.8 32.6
17 HP line before Expansion loop (Trench -3) 31.2 32.2
18 HP line after Expansion loop (Trench -3) 31.2 35.3
19 HP line at Dummy end (Trench -3) 31.5 34.8
20 MP Down-comer line (Trench-3) 30.8 30.8
21 MP line Dummy end (Trench -3) 30.4 30.4
22 HP Down-comer line (Trench-2) 32.9 32.9
23 HP line before Expansion loop (Trench -2) 39.8 39.8
24 HP line after Expansion loop (Trench -2) 37.8 37.8
25 HP line at Dummy end (Trench -2) 36.8 36.2
26 MP Down-comer line (Trench-2) 33.9 33.5
27 MP line before Expansion loop (Trench -2) 36.4 35.2
28 MP line after Expansion loop (Trench -2) 38.5 36.5
29 MP line Dummy end (Trench -2) 45.5 37.5
30 MP Line at Dummy point (On Howrah Bridge) 31.1 32.4
31 HP Line at Isolation valve for 4-Roll Calendar(On Howrah Bridge) 32.5 34.1
32 Steam Line at Loop-1 (MFG) 32.4 34.7
33 Steam Line at Loop-2 (MFG) 33.4 35.2
34 Steam Line at Loop-3 (MFG) 34.4 32.7
35 Steam Line at Loop-4 (MFG) 33.7 31.9
36 Steam Line at Loop-5 (Mixing) 31.8 32.6
37 Steam Line at Loop-6 (RMS) 31.3 32.2
38 Steam line at Mixing PRS 31.8 35.3
39 Steam line at Calendar PRS 36.0 34.8
INSULATION SKIN TEMP.
TRAP CHECK SHEET

10. 1
BOILER EFFICIENCY MONITORING
Date Coal Consumed [MT]
Steam Generation
[MT]
GCV of Coal (ARB)
[ K.Cal/Kg]
Boiler Efficiency
[%]
Average Load on
Boiler [%]
09-09-22 28.12 104.96 4200 51.13 21.87
10-09-22 29.64 108.63 4200 50.21 22.63
11-09-22 26.60 109.63 4200 56.46 22.84
12-09-22 28.12 110.62 4200 53.89 23.05
13-09-22 27.77 111.53 4200 55.02 23.24
14-09-22 26.56 110.03 4200 56.75 22.92
15-09-22 26.56 116.34 4200 60.01 24.24
16-09-22 23.24 112.21 4200 66.15 23.38
17-09-22 24.07 105.00 4200 59.76 21.88
18-09-22 27.39 102.72 4200 51.38 21.40
19-09-22 23.24 104.15 4200 61.39 21.70
20-09-22 25.73 105.39 4200 56.11 21.96
21-09-22 27.36 107.57 4200 53.86 22.41
22-09-22 28.88 112.00 4200 53.13 23.33
23-09-22 28.12 114.25 4200 55.66 23.80

11. COAL ANALIYSIS REPORT (UTILTIY LAB)
MONTH - SEPT-2022
MAHANSARIA TYRES PVT. LTD. PANOLI
MTPL UTILITY LAB
Date Vehical No.
GCV (ARB) GCV (ADB) Ash
Total
Moisture
(ARB)
Inherent
Moisture
Volitile
Matter
Fixed
Carbon
4800 ± 100
K.Cal/Kg
5700 ± 100
K.Cal/Kg
5 - 7 % 29 ± 2 % 11% 40 - 42%
3/9/2022 GJ 21 Y 8823 4693 5969 6.04 34.32 16.46 41.35 36.15
3/9/2022 GJ 16 AW 2255 4662 6061 5.93 34.96 15.44 41.72 36.91
3/9/2022 GJ 16 AU 9558 4665 5869 6.11 31.89 14.32 39.61 39.96
05/09/22 GJ 16 AV 1560 4555 5721 8.18 33.33 16.27 38.67 36.88
05/09/22 GJ 16 AV 1888 4838 5896 7.06 32.66 17.94 41.39 33.61
05/09/22 GJ 16 AV 4049 4812 5964 6.39 33.00 16.96 40.02 36.63
06/09/22 GJ 21 W 7405 4643 5909 8.22 34.18 16.23 36.82 38.73
06/09/22 GJ 21 W 7662 4727 5985 7.25 33.72 16.08 37.28 39.39
07/09/22 GJ 21 V 0433 4690 5964 7.64 34.57 16.80 36.76 38.80
07/09/22 GJ 21 W 6708 4884 6178 6.59 31.52 13.37 41.81 38.23

12. 1
ACTIVITY INITIATED FOR FLY ASH % MONITORING
BOILER FLY ASH ANALYSIS REPORT MONTH- SEPT-2022
BOILER FLY ASH ANALYSIS REPORT MONTH- AUG-2022
Date UNBURN %
9/7/2022 10.86%
9/11/2022 7.2%
9/18/2022 8.34%
9/20/2022 7.67%
9/21/2022 8.9%
9/22/2022 8.21%
9/23/2022 7.82%
9/24/2022 7.02%
Date UNBURN %
8/5/2022 10.22%
8/9/2022 10.37%
9/10/2022 9.35%
8/17/2022 8.97%
8/21/2022 9.89%
8/25/2022 8.05%
8/27/2022 9.61%
8/30/2022 10.02%

13. 1
ACTIVITY INITIATED FOR DEAERATOR TEMP.
DEAERATOR TEMPERATUR REPORT MONTH- AUG-2022
DATE 7AM 9AM 11AM 1PM 3PM 5PM 7PM 9PM 11PM 1AM 3AM 5AM
8/4/2022 90 90 88 91 96 85 92 90 90 92 90 92
8/5/2022 92 96 94 99 96 93 94 93 93 91 90 91
8/6/2022 90 90 92 90 92 90 93 95 90 96 91 92
8/7/2022 95 88 88 82 87 90 92 93 91 94 96 92
8/8/2022 92 92 90 92 95 95 95 94 90 92 95 91
8/9/2022 90 95 92 90 89 87 91 90 95 93 94 91
8/10/2022 91 88 90 87 90 93 95 93 90 91 94 96
8/16/2022 95 90 95 95 96 93 91 91 95 92 93 95
8/17/2022 93 90 91 90 90 95 95 95 96 92 93 91
8/18/2022 98 99 97 98 97 97 100 99 98 91 96 95
8/19/2022 90 97 93 91 92 91 93 97 92 90 91 90
8/20/2022 95 95 93 90 96 94 94 97 98 97 96 96
8/21/2022 94 96 92 96 93 97 89 90 92 93 96 93
8/22/2022 94 98 94 95 93 94 90 90 92 90 91 97
8/23/2022 94 96 90 90 97 90 98 95 91 94 98 90
8/24/2022 92 87 98 95 97 93 96 93 90 91 94 91
8/25/2022 97 98 92 95 90 93 96 95 94 98 92 97
8/26/2022 92 96 98 95 95 92 94 93 90 94 96 94
8/27/2022 96 91 90 90 90 92 92 92 96 91 90 95
8/28/2022 95 89 89 91 89 92 89 92 94 97 90 94
8/29/2022 95 98 92 94 91 93 94 93 91 96 96 94
8/30/2022 91 92 90 92 94 93 90 92 95 96 99 91
8/31/2022 94 101 98 95 99 97 96 95 94 93 96 97
AVG. DEAERATOR TEMP. 94 *C /DAILY

14. WAY FORWARD – STEAM & FUEL
CFT – Steam & Fuel :-1. Mr. M.M. Kidwai, 2. Mr. Sudip Banerjee 3. Mr. Santosh 4. Mr. Amit Rathore
Energy Conservation Plan & Status
S.No. Job Description Action Responsibility TCD
1 BU-1 MIXER /4-ROLL area steam line pressure reduced from 16
bar to 7 bar
Tapping change over from HP to
LP steam line
Kidwai Ji DONE 17.07.2022
2
MAIN HEADER TO STEAM PRS condensate Darin line cover with
ROP ,Replace with LRB /Alum. Cladding ,total 9 no's pipeline
app 60-meter 1/2" pipeline
Insulatio provide with clading Santosh Done 23.09.2022
3
CURING TO MIXER PROCESS OIL tank condensate drain line
open condition, cover with LRB /Alum. cladding ,total 15 no's
pipeline app 120-meter 1/2" pipeline
Insulatio provide with clading Santosh Work going on
4
Continously steam used in process oil & day tank ,Steam valve
on/off base on temp .
On/Off valve to be provided
based on temp.
Amit Rathore Ji 10/10/2022
5 All curing presses flot type steam trap to be tunned ,TD trap
servicing to be done
Trap valve to be tunned Sudeep Banerjee DONE 03.08.2022
6 curing area over head mixer area 2" steam line to be insulated
app. 18 mtr
Insulatio provide with clading Santosh DONE 16.08.2022
7
RO-1 Reject water recovery project through Softner plant
Tank arranged & pipeline work
going on
Santosh 5/10/2022

15. Thank You