1. EXECUTIVE SUMMARY FOR OVERALL THERMAL SAVINGS IN IRON & STEEL INDUSTRY Sr.Areas and Energy conservation Measures Savings in Respective Units Units for Savings per year Annual Saving in Rs. Investment in Rs. Payback Period, Months 1 Saving in fuel consumption by reducing the excess air up to 12 % 345.16 & 7.94 KL of FO & KL of LDO 61,05,857 No Investment 2 Saving in fuel consumption by improving the furnace insulation 999.73 & 79.98 KL of FO & KL of LDO 1,93,95,0131,62,63,41410.06 3 Saving in electricity consumption by replacing electrical heaters for fuel heating by briquette/biomass fired thermic fluid heater 12,32,181KWh/year31,62,59927,50,00010.43 4 Saving in fuel consumption by preheating the combustion air upto 250 oC in furnaces and upto 125 oC in Thermo packs 753.33 & 13.35 KL of FO & KL of LDO 1,29,01,17694,88,1878.83 5 Saving in furnace oil consumption by emulsification technology 718.50KL of FO1,22,14,49582,94,2548.15 6 Saving by replacement of (80%) oil firing of furnace by Producer gas firing 19159.99 & 1239.35 KL of FO & KL of LDO 8,46,43,2069,64,56,56113.67 7 Saving in LDO Consumption by reducing the evaporation loss of hot water pickling tanks 40.05KL of LDO12,01,5002,72,8772.73 8 Saving by fuel switching from LDO to briquettes/biomass fired thermic fluid heaters 498.00KL of LDO96,07,49670,00,0008.74 9 Saving by Fuel Switching from LDO to briquette/Coal based Gassifier in SMS-I &II 2840KL of LDO4,46,82,6662,00,00,0005.4 Total 10,31,64,9466,40,68,732 7.45

2. FINDINGS OF ELECTRICAL ENERGY AUDIT 1.Saving in induction furnace by increasing heat rate 2.Energy Saving by reducing compressed air leakages 3.Saving By installing VFD on combustion Blowers of Furnaces 4.Saving in cooling tower fan power consumption by installing ATC 5.Saving By installing proper size of pump 6.Saving in lighting power consumption can be achieved by 7.Replacement of MV Lamps with MH Lights

3. Sr.Section Name Savings in Kwh/Year Annual Saving in Rs. Investment in Rs. Payback Period, Months % Section 1VAL (G-23)422541816952000001 Year0.15 % 2VAL (G-22)1386755963022720506 Months0.44 % 3VAL (G-32)1384845954801038000 1 Year 8 Months 2.88 % 4VPL (G-75)1442104620104723594756 Months6.00 % 5VSL (G 1/3)56711243856427000 1 Years 10 Months 0.75 % 6Bebitz (140/2)29534112699669559009 Months4.08 % 7VPL (G-2)3144936216938825256003 Months11.35 % 8VFL (140/1)28355212192741542700 1 Year 3 Months 3.32 % 9VPL (MAAN)1342607577321041760008 Months11.66 % Total688466474230698296040556 Months EXECUTIVE SUMMARY FOR OVERALL ELECTRICAL SAVINGS

4. Increase in melt rate by using shredded scrap Analysis Based on June & July-2009 ParametersMelt Rate (Kg/Min)Specific energy consumption (KWh/MT) for MS AverageMaxMinAverage SMS-I10759224573 SMS II (When 3 furnaces are in operation) 11516525567 SMS II (When 2 furnaces are in operation) 13619975538 SMS II (Combined) 123 19925 553 Analysis Based on Nonv-2009 (11 Days Data) ParametersMelt Rate (Kg/Min)Specific energy consumption (KWh/MT) for MS AverageMaxMinAverage SMS-I12014672536 SMS II (When 3 furnaces are in operation)139189105516 SMS II (When 2 furnaces are in operation)142169120519 SMS II (Combined) 141189105508 Increase in melting rate: SMS-I= 13 Kg/Min SMS II (When 3 furnaces are in operation)= 24 Kg/Min SMS II (When 2 furnaces are in operation)= 06 Kg/min Decrees in KWh/MT: SMS-I= 37= Rs 160/ MT SMS II (When 3 furnaces are in operation)= 51= Rs 220 / MT SMS II (When 2 furnaces are in operation)= 20= Rs 86 / MT

5. EXECUTIVE SUMMARY FOR THERMAL SAVINGS IN FORGING SECTION Sr. Areas and Energy conservation Measures Savings in Respective Units Units for Savings per year Annual Saving in Rs. Investment in Rs. Payback Period, Months 1 Saving in fuel consumption by reducing the excess air up to 12 % 121.26KL/year20,61,420 2 Saving in furnace oil consumption by improving the furnace insulation 253.77KL/year43,14,12634,80,2269.67 3 Saving in electricity consumption by replacing electrical heaters for furnace oil heating by briquette/biomass fired thermic fluid heater 262800KWh/year6,74,5206,00,00010.67 4 Saving in furnace oil consumption by preheating the combustion air upto 250 oC 192.34KL/year32,69,82626,64,7409.77 5 Saving in furnace oil consumption by emulsification technology 194.21KL/year33,01,59320,29,1967.37 6 Saving by replacement of (80%) oil firing of furnace by Producer gas firing 5178.97KL/year1,76,08,4972,23,99,01615.26 Total 1,36,21,48587,74,1627.73

6. Sr. Area and Energy conservation Measures Savings in Respective Units Units for Savings Annual Saving in Rs. Investment in Rs. Payback Period, Months VFL- II 1 Energy Saving by reducing compressed air leakages up to 5%1038145KWh/Year44640245000002 Months 2 Saving in cooling tower fan power consumption by installing ATC5223KWh/Year22459500002 Years 3 Saving By installing VFD on combustion Blowers of Furnaces44723KWh/Year192309340000 1 Year 9 months 4 Saving in lighting power consumption can be achieved by replacement of MV Lamps with MH Lights18576KWh/Year79876158800 1 Year 11 Months Total1106667KWh/Year475866810488006 Months EXECUTIVE SUMMARY FOR ELECTRICAL SAVINGS IN FORGING SECTION

7. Saving in electricity consumption by replacing electrical heaters for furnace oil heating by briquette/biomass fired thermic fluid heater Sr. No. FurnaceBriquette Required by replacing Electricity with Briquette/biomass fired Thermic Fluid Heater (Kg/year) Annual Cost of Briquette/biomass in Rs. Annual Saving in Switching to Briquette/biomass fired Thermic Fluid Heater in Rs./year % Saving 1 Pusher Flange Furnace-2 6278.0025112.004496864.17 2 Box Flange Furnace-2 9417.0037668.006745264.17 3 Pusher Flange Furnace-3 3139.0012556.002248464.17 4 Pusher Flange Furnace-6 3139.0012556.002248464.17 5 Box Flange Furnace-4 28251.00113004.0020235664.17 6 Pusher Flange Furnace-5 6278.0025112.004496864.17 7 Pusher Flange Furnace-7 9417.0037668.006745264.17 8 Pusher Furnace near 28 inch 6278.0025112.004496864.17 9 Batch annealing Furnace-2 12556.0050224.008993664.17 10 Bogie-3 9417.0037668.006745264.17

8. Saving in furnace oil consumption by changing the recuperator Sr. No FurnaceAnnual furnace oil consumption, KL/year % Saving in fuel Consump tion Saving in furnace oil consumption, KL/year Saving in Rs./year Reduction in lit/MT 1 Pusher Flange Furnace-2 6000.060.396588 168.20 to 168.18 2 Box Flange Furnace-2 9604.9347.37805261 168.20 to 165.57 3 Pusher Flange Furnace-3 6002.2813.70232958 168.20 to 167.20 4 Pusher Flange Furnace-6 6003.0518.30311015 168.20 to 167.20 5 Box Flange Furnace-4 9602.9127.98475614 168.20 to 166.63 6 Pusher Flange Furnace-5 6003.7622.55383304 168.20 to 166.63 7 Pusher Flange Furnace-7 6003.8723.24395136 168.20 to 168.26 8 Pusher Furnace near 28 inch 6004.8128.84490328 168.20 to 166.60 9 Bogie-3 3602.8810.37176209 168.20 to 167.63

9. Immediate action to be taken 1.Reduction in Excess Air supply 2.Maintaining the temperature of combustion air above 250 O C 3.Reduce the radiation losses by improving the insulation 4.Reduction in air leakages of compressor 5. Installing VFD on combustion blowers of Furnaces 6.Avoiding double pumping and replacing existing pump with proper size pump