Comprehensive energy analysis and BESS deployment for JSPL, spanning DSM penalty avoidance, demand charge management, Exchange energy arbitrage, and digital twin modeling for one of India's largest steel producers.
Jindal Steel & Power Limited (JSPL), one of India's largest integrated steel producers, engaged Ingro Energy for comprehensive energy analysis and BESS deployment across their operations. The project spans JSPL's Angul facility in Odisha (featuring 2×70 MW Electric Arc Furnaces and a captive thermal power plant) and their Raigarh operations, addressing DSM penalty avoidance, demand charge management, reactive power optimization, and Exchange energy arbitrage.
This is one of Ingro's most technically complex industrial engagements, involving deep analysis of real plant metering data, ETAP power system studies, Exchange market integration modeling, and BESS sizing optimization for a facility with extreme load dynamics.
Extreme load dynamics, Two 70 MW Electric Arc Furnaces creating ~37 swing events per day with ~40 MW average deviation per event
DSM penalty exposure exceeding ₹30 Crore/year from 12-16 minute deviation windows during EAF switching
Demand charge overruns, total load reaching ~450 MW, breaching the 430-440 MW contractual demand
Infirm power waste, captive thermal plant generating excess power, with infirm energy increasing 93% year-over-year
Poor power factor from EAFs (0.70-0.85) driving reactive power charges
Complex grid interconnection, 33 kV BESS into 220 kV and 400 kV buses requiring protection coordination
Comprehensive Plant Analysis: Analyzed 12 months of 1-second interval metering data identifying EAF cycling patterns, DCPP ramp limitations, and grid dynamics
BESS Sizing Optimization: Parametric simulation proving 15 MW/30 MWh captures majority of savings with better ROI. Ran 12 trading strategies including MILP, DP, and Q-Learning
Exchange Arbitrage Integration: Comprehensive commercial model integrating Exchange DAM/RTM prices, open access charges, and full cost accounting
ETAP Power System Study: Load flow, short circuit (40 kA at 33 kV), and protection coordination for 15 MW BESS interconnection
Digital Twin: Dynamic model of JSPL's entire electrical infrastructure (400 kV / 220 kV / 33 kV) to simulate BESS impact
Steel Manufacturing, Angul & Raigarh, India
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