BEE Knowledge Exchange Platform 2015 Vedanta Smelter ,Jharsuguda - - PowerPoint PPT Presentation

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BEE Knowledge Exchange Platform 2015 Vedanta Smelter ,Jharsuguda - - PowerPoint PPT Presentation

Dec 27, 2023 266 likes •750 views

Best Practices in Energy Efficiency in Aluminium Smelting BEE Knowledge Exchange Platform 2015 Vedanta Smelter ,Jharsuguda VISION, MISSION & VALUES Entrepreneurship VISION We will be the worlds most admired Sustainability Growth

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SLIDE 1

Best Practices in Energy Efficiency in Aluminium Smelting BEE Knowledge Exchange Platform – 2015 Vedanta Smelter ,Jharsuguda

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SLIDE 2

Entrepreneurship Growth Excellence Trust Sustainability

VISION, MISSION & VALUES

VISION

“We will be the world’s most admired

company that consistently defines the leading standards in our businesses, making our stakeholders proud to be associated with us” VALUES MISSION

“Our mission is to be a world class,

diversified resources company that provides superior returns to its shareholders, through high-quality assets, low-cost operations and responsible corporate citizenship.”

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SLIDE 3

NATURAL RESOURCE-OUR BUSINESS “Think Locally Act Globally”

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SLIDE 4

5 LTPA Aluminium Smelter 1215 MW CPP 12.5 LTPA Aluminium Smelter 2400 MW IPP

VEDANTA - JHARSUGUDA

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SLIDE 5

MAKING OF ALUMINIUM

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SLIDE 6

ALUMINIUM ELECTROLYSIS CELL

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SLIDE 7

ENERGY CONSERVATION

“Neither a campaign nor an initiative It is our habit and culture”

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SLIDE 8

98% 2% Electricity Fuel

ALUMINIUM – ENERGY INTENSIVE

32% 68% Energy Other Cost

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SLIDE 9

ENCON PROJECTS (2011-14)

  • No. Of ENCON Projects

81 Energy Savings (M kWh) 385 Energy Savings (MT of fuel) 4020 INR Saving(Cr.) 112 INR Investment (Cr.) 3

“Small investments and high returns”

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SLIDE 10

MAJOR ENERGY SAVING PROJECTS

Sl.No. Title of the Project Energy Savings (MWh/Annum)

1 Reduction in Stub To Carbon voltage drop 109824 2 Reduction in Pot voltage . 62078 3 Improvement of current efficiency of pots. 45060 4 Implementation of slotted anode in pots 34330 5 Reduction of compressed air consumption. 19535 6 Reduction of dead pot voltage and crossover voltage . 8715 7 Optimization of Compressor running. 5310 8 Online addition of pots into circuit by fuse blown technology. 2324 9 HTM heater set point optimization in GAP. 1808 10 Reduction of the Specific Energy consumption of Wire Rod Mill. 1269 11 Improve Rodding shop availability. 589

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SLIDE 11

MAJOR FUEL SAVING PROJECTS

Sl.No. Title of the project Fuel Savings (MT/Annum)

1 Reduction of HFO consumption in Anode Baking Furnace 3051 2 Optimized usage of compressor in Metal Transport Vehicle 34 3 Reduction of diesel consumption in production vehicles by improving engine efficiency 27 4 Optimization of LPG burner use for ingot Casting. 15

“Save Today for a better Tomorrow”

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SLIDE 12

War Room Discussion

Asset Optimization Trophy

SMALL GROUP ACTIVITIES 2014-15

War Room Project Champions

Rectifier

  • No. Of

Projects : 4

  • Yearly

Saving : 355 MWh

  • Employees

:10

Utility

  • No. Of

Projects : 6

  • Yearly

Saving : 4082 MWh

  • Employees

: 8

Cast House

  • No. Of

Projects : 5

  • Yearly

Saving : 3791 MWh

  • Employees

: 25

Carbon

  • No. Of

Projects : 21

  • Yearly

Saving : 13087 MWh

  • Employees

: 120

Potline

  • No. Of

Projects : 6

  • Yearly

Saving : 184 MWh

  • Employees

: 200

Yearly Saving :- 22 M KWh

“We value every small Contribution”

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SLIDE 13

ENERGY CONSUMPTION TRENDS

45 50 55 60 2011-12 2012-13 2013-14 2014-15 TARGET

59 55 54 53.5 52.9

Total SEC-Smelter (GJ/MT)

HFO-Kg/MT

20 40 60 80

2011-12 2012-13 2013-14 2014-15 Target

70 64 54 48.2 45

HF0-Kg/MT

13400 13650 13900 14150 14400 14650

2011-12 2012-13 2013-14 2014-15 Target

14623 14024 13818 13806 13566

AC-KWh/MT

“Save What ?? Save a Watt”

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SLIDE 14

ENCON JOURNEY

2010 2011 2012 2013

Energy Audit by CII Energy Audit by TERI EnMS Implemented ISO 50001 Certified CII Award BEE Award

2014

GMEA award CII Award Russian Govt.- Award NECA -1st Prize

Fuse Technology Slotted Anode Cathode Clamp Drop HFO & Stub to Carbon

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SLIDE 15

ENERGY OBJECTIVES 2015-2016

  • Reduce DC Energy Consumption from 13566 to 13322 KWh/Ton
  • Reduce Auxiliary Energy Consumption from 397 to 382 KWh/Ton
  • Reduce HFO Consumption from 48.2 to 45Kg/Ton
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SLIDE 16

REVIEW STRUCTURE

Formation of Energy Cell Energy review structure

“Top to Bottom approach”

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SLIDE 17

IT ENABLEMENT

Energy Efficient Procurement Capex Energy Impact Assessment MES Online Flash Report

“Automation leads to Perfection”

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SLIDE 18

Magnetic Field Compensation Of Electrolysis Cells

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Cathode Modification Of Electrolysis Cells Up-gradation of Pot Control & Feeding System

ROAD MAP TOWARDS BENCHMARK

Waste Heat Recovery

“Measure to Control - Benchmark to Better”

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SLIDE 19

Cathode thode Mo Modi dification ication

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SLIDE 20

CATHODE MODIFICATION Savings/Year – 88 M KWh

Technical Invention Result (kWh/MT)

Change in Geometry of collector bar 76.8 Change in % of graphite in cathode block 60.8 Change in % of graphite in ramming paste 32.0

TOTAL ENERGY SAVINGS 169.6

“Every Unit counts”

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SLIDE 21

Re Reductio duction n of f HFO FO Co Consump nsumption tion

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SLIDE 22

PREHEATING CURVE MODIFICATION

RESULT

  • Preheating

temperature increased from 740°C to 800°C

  • HFO injection reduced

from 78 to 76 Hrs.

Preheating curve modified to improve pitch volatile combustion

300 400 500 600 700 800 900 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

Temperature (°C) Hrs

Pre Heating Curve

Initial Final

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SLIDE 23

REDUCTION OF FALSE AIR INGRESS

Gap between burner stand & ring

Gap covered with packing coke

The gap between the flue and burner base ,flue hole cover , thermocouple base had false air intake

Effective sealing by Packing Coke

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SLIDE 24

REDUCTION OF RADIATION LOSS

BEFORE

  • Flue Hole Covers were modified to reduce radiation

losses

  • Metallic cylinder and nets were replaced with ceramic

wools and holding plates

  • Insulation in the new design is farther from heat source
  • Cast Iron Rings were replaced by refractory rings
  • Redesigned covers surface temperature was lowered

by 73°C

  • Modified covers were Rs.700 cheaper than the original

design AFTER

100 120 140 160 180 200 220 240 260

Before After

258 185

Cover Surface Temp.(°C)

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SLIDE 25

 HFO consumption reduced from 63.8 to 46.6 kg/ MT of baked anode  Annual HFO Saving is 4800 MT resulting in cost saving of 20 Cr.

REDUCTION OF HFO CONSUMPTION

45 50 55 60 65

HFO CONSUMPTION KG/MT BAKED ANODE

“Improvement is an Infection”

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SLIDE 26

Re Reductio duction n of f St Stub ub to Ca Carbon rbon mV mV Dr Drop

  • p
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SLIDE 27

mV Carbon Stub Cast Iron

REDUCTION OF STUB TO CARBON mV DROP

Resistance at the gap filled by Cast Iron between the Steel Stub & Carbon Anode

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SLIDE 28

CAST IRON COMPOSITION

3.50 3.70 3.90 4.10 4.30 4.50 4.70 4.90 5.10 Apr/13 May/13 Jun/13 Jul/13 Aug/13 Sep/13 Oct/13 Nov/13 Dec/13 Jan/14 Feb/14 Mar/14 Apr/14 May/14 Jun/14 Jul/14 Aug/14 Sep/14

Cast Iron Carbon Equivalent

Cast Iron C.E lsl usl

The contact resistance between Cast Iron & Carbon is a function of the Contact Pressure. The Contact Pressure is a function of Cast Iron Composition. The Carbon Equivalent of the Cast Iron was improved by Graphite addition instead of Amorphous Carbon

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SLIDE 29

STUB HOLE DESIGN CHANGE

The button at the bottom of the stub hole was removed to improve the contact pressure between Cast Iron & Carbon by reducing the air gap at the corners

BEFORE AFTER

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SLIDE 30

REDUCTION IN STUB TO CARBON mV DROP Reduction in Stub to Carbon mV drop = 66 mV per Pot Savings/Year is 110 M KWh

mV 79

75 85 95 105 115 125 135 mV

Stub To Carbon mV Drop

“Every milli Volt Counts”

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SLIDE 31

Re Reductio duction n in n Ca Cast st Ir Iron

  • n

Sp Spill illage age

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SLIDE 32

Reduction in Cast Iron Spillage

  • Cast iron spillage during casting
  • Cleaning and Re-melting it
  • Spilled cast iron is 127 ton/month.

INTERVENTION:

  • Ladle Spout Modification.
  • Cabin visibility improved
  • Cleaning of bath from stubs

PROBLEM DEFINITION: BENEFITS:

  • Cast iron spillage reduced by 87 ton/month.
  • Energy saved 0.7 M KWh/Year
  • 12000 Man-Hours saved per year.
  • Total cost savings is Rs. 25 lakhs / year.

450mm

“Opportunity Everywhere”

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SLIDE 33

Co Cooling ling Fa Fan R n Runn unning ng Ho Hour urs

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SLIDE 34
  • We required higher draft to reduce HFO

consumption which will increase power consumption.

  • We searched for opportunities to save energy.

INTERVENTION:

  • Cooling fans stopped 4 Hours in every fire cycle
  • Energy consumption from 6912 KWH/day to

5760 KWH/day

  • Energy saving: 0.4 M KWh / Year
  • Cost saving: Rs. 10 lakhs / year

BENEFITS: PROBLEM DEFINITION:

Baking Furnace Cooling Fans “Conserve here to Consume there”

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SLIDE 35

Ene Energy y Re Redu duction ion Bi Billet et Ho Homo mogen genizat zation ion

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SLIDE 36

PROBLEM DEFINITION:

  • Power consumption in homogenizing furnace was

high at 220KWH/ton.

  • Replaced Rock wool to Rock wool + Cera wool sandwich
  • Power consumption reduced from 220 KWH/ton to 212 KWH/ton.
  • Energy saved 1 M KWh/ year
  • Cost savings is Rs. 25 lakhs/year.

INTERVENTION BENEFITS

Energy saving in homogenizing furnace “Kaizen for a Khazana”

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SLIDE 37

Re Reductio duction n in n ID F ID Fan an Power wer Co Consumptio nsumption

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SLIDE 38

PROBLEM DEFINITION:

  • Power consumption of ID fan running with loading
  • f 16.82 MW.
  • ID fan loading reduced to 16.33 MW.
  • Energy savings – 4.3 M KWh / Year
  • Cost savings- Rs.1 Crore / Year

INTERVENTION BENEFITS

  • Pot flow balancing.
  • Hooding efficiency improvement
  • Leakage reduction
  • Improved gaskets for flange joints

Energy savings in FTP ID fan

16.2 16.3 16.4 16.5 16.6 Jan-15 Feb-15 Mar-15 Apr-15

ID FAN POWER CONSUMPTION(MW)

“Basics karo Bindass Raho”

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SLIDE 39

Com

  • min

ing g To Together ther is is Bu Busi siness ess Th Thin inkin ing g To Together ther is is Proces cess Wor

  • rki

king ng To Together ther is is Su Succe ccess ss Keeping ing To Togeth ther er is is P Progr gres ess

“Bottom to Top Approach”

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SLIDE 40

Efforts towards GHG emission reduction :

  • Adoption of new technology.
  • Stepping in towards renewable energy

sources.

  • Creating awareness among employees and

stakeholders.

  • Reduction in no. of light vehicle by

50%.Vehicle with aging less than 3 years

  • nly allowed & ensuring PUC certificate for

every vehicle.

  • Increasing the load ability in transportation

to reduce carbon emission

Inventory Mitigation

Year Scope 1 Emissions CO2emission (MT) Scope 2 Emissions CO2 emission (MT) Scope 3 Emissions CO2emission (MT) Total reduction in emissions intensity since baseline year study CO2e (MT) FY 2012-13 (Base Year) 16330076 398 Not determined 16330474 FY 2013-14 15948488 2607 207040 15951095

CARBON FOOT PRINT ACTIVITIES

Drastic reduction of 2.3% from base year (2012-13)

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SLIDE 41

HENCON & SIEMENS OUR PARTNERS

Automation in cooling tower to control fan switching in bake oven Reactor Venturi modification and air chamber plug modification

  • f all air slide air chamber

in FTP Automatic switching of lighting circuit Elimination of unwanted usage

  • f compressor in

MTV Checking of pressure problem in MTV by using plant air Energy saving- 0.7 M KWh/year

“Sabka Saath Sabka Vikash”

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SLIDE 42

Harnessing Solar Energy Solar Water Evaporator Eco Ventilators

Energy Saving – 5000 KWh/year Solar Cell & LED Lighting

RENEWABLE ENERGY SOURCES

“Future of Energy”

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SLIDE 43

Title Of The Project Potential Savings/Annum

  • 1. Magnetic Field Compensation

324000 MWh

  • 2. Cathode Modification
  • 3. Up-gradation of Pot Control & Feeding System
  • 4. Reduction of Compressed air consumption

4380 MWh

  • 5. Use of High Density High weight anodes to reduce HFO &

Energy consumption 360MT Carbon, 833 MWh, 220 MT HFO

  • 6. VVFDs in fans and pumps

700 MWh

  • 7. Reduction of HFO consumption by waste heat recovery

460 MT

  • 8. Use of Solar Water Heater

120 MWh

  • 9. Use of Energy Efficient Lights

83 MWh

  • 10. Solar Photovoltaic Cell in administrative block.

60 MWh

  • 11. Lighting energy savers in street lighting system.

31 MWh

  • 12. Bio gas Plant for cooking in canteen.

1642 Kg 13.Waste Heat recovery from flue gases from BO & Potroom To Be Estimated

  • 14. New Technology to reduce RO Rejections

To Be Estimated

Our Plans For A Better Tomorrow….

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SLIDE 44

AWARDS & RECOGNITIONS

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SLIDE 45
  • Energy Conservation Category

 National Award for the “Most Energy Efficient unit in Aluminium sector” from honorable President of India.  Recognized as “Excellent Energy Efficient Unit” at 15th National Award for “Excellence in Energy Management” organized by CII.

  • Sustainable Performance Category

 Silver Category IMEA Award by Frost & Sullivan.  "Challengers Award - Mega Large Business" against "Frost & Sullivan’s Green Manufacturing Excellence Awards 2014".  “Odisha EHS Award” by CII.  CSR award under two categories at “Odisha CSR conclave 2014”  Chairman’s Performance Award – Q1 , Q2 CY’13 & Q1, Q2 CY’14.  Sustainability Award – Winner in H2 & Runners up in H1 of 2013-14.  Engineering Excellence Award 2013 by Engineering Watch for best innovation and engineering Marvel.  CPP has won 14th National Award For Excellent Energy Efficient Unit-2013 By CII.  1st Prize for National Energy Conservation Award 2012 by BEE.  International Green Apple Award for reduction in GHG emission by introduction of slotted anodes for Smelter-I.

AWARDS & RECOGNITIONS

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SLIDE 46

"The more energy we save, the more we save the next generations" “We are focussing on renewable energy not for laurels but to lighten homes

  • f the poor and bring a

change in their lives" “Energy can be saviour of generations”

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SLIDE 47

It takes To transform

One will A million

We harness our Collective will

Energy Conservation A Way of Life

To make At Vedanta