Introduction
JSW, a leading steel manufacturer, is recognized for its commitment to innovation, quality, and sustainability. Operating in one of the most energy-intensive sectors, JSW faced critical challenges in energy management, process optimization, and emissions reduction. To address these challenges, JSW partnered with Greenovative Energy to deploy the GreenErgy platform, transforming its approach to energy efficiency and sustainability while maintaining production excellence.
Challenges
JSW’s energy management challenges included:
- Energy Flow Visibility Across Processes: Limited visibility into energy flows and difficulty correlating energy usage with production hinder optimization opportunities.
- Process Optimization for Sustainability: Lack of energy and emissions visibility impacts sustainability reporting and emissions reduction targets.
- Energy Efficiency in Furnaces and Rolling Operations: High energy consumption, equipment inefficiencies, and limited SEC monitoring affect optimization and efficiency.
- Integration of Waste Heat Recovery Systems: Untapped energy-saving potential due to limited utilization and infrastructure alignment challenges.
Solution:
The GreenErgy Platform GreenErgy provided JSW with a comprehensive energy management solution tailored to its operational needs. The platform’s key features and capabilities included:
- Centralized Energy Flow Monitoring:
- Implemented IoT-enabled sensors to track energy flows across furnaces, rolling mills, and other key processes in real-time.
- Provided a unified dashboard offering granular visibility into energy usage patterns and their correlation with production output.
- Sustainability-Driven Process Optimization:
- Integrated AI-powered analytics to monitor energy and emissions data across processes, enabling accurate sustainability reporting.
- Delivered actionable insights to help JSW achieve emissions reduction targets while maintaining consistent product quality.
- Furnace and Rolling Efficiency Tools:
- Implemented AI-driven SEC (Specific Energy Consumption) monitoring within the GreenErgy platform, offering real-time insights into energy usage at furnaces and rolling mills.
- Provided dynamic benchmarking dashboards to highlight performance gaps and suggest optimization strategies.
- Delivered predictive analytics to forecast equipment energy demands, enabling proactive interventions to minimize losses.
- Waste Heat Recovery System Integration:
- Integrated advanced analytics to evaluate and simulate waste heat recovery opportunities, guiding data-driven decisions for power generation and preheating processes.
- Provided a digital framework within the GreenErgy platform to track heat recovery performance and align reuse systems seamlessly with existing operations.
Results and Impact
The deployment of the GreenErgy platform delivered measurable improvements for JSW:
- Enhanced Energy Efficiency:
- Achieved a 15% reduction in specific energy consumption (SEC) across furnaces and rolling mills.
- Optimized energy allocation, reducing waste and improving overall utilization.
- Sustainability Advancements:
- Reduced carbon emissions by 18%, aligning operations with global sustainability benchmarks and ESG commitments.
- Improved sustainability reporting accuracy, enhancing transparency with stakeholders.
- Operational Excellence:
- Minimized equipment downtime through predictive maintenance, ensuring consistent energy performance.
- Improved throughput and product quality by addressing inefficiencies in furnaces and rolling operations.
- Waste Heat Recovery Utilization:
- Recovered and reused 20% of waste heat, significantly reducing energy demand from external sources.
- Enhanced energy resilience by integrating heat recovery systems into existing operations.
Conclusion
JSW’s partnership with Greenovative Energy underscores the transformative potential of advanced energy management solutions. By adopting the GreenErgy platform, JSW achieved significant energy efficiency improvements, reduced emissions, and enhanced operational reliability. This collaboration demonstrates how innovative technologies can drive sustainability and operational excellence in energy-intensive industries.
Greenovative Energy continues to empower organizations with tailored energy management solutions that unlock value, drive resilience, and accelerate their sustainability journeys.
About Greenovative
Greenovative Energy specializes in next-generation energy management solutions, seamlessly integrating AI, IoT, and cloud technologies to redefine operational efficiency. Our flagship GreenErgy platform empowers organizations to optimize energy ecosystems with precision and scalability.
Visit us at: www.greenovative.com
