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 world’s most admired Sustainability Growth 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, Excellence Trust diversified resources company that provides superior returns to its shareholders, through high-quality assets, low-cost operations and responsible corporate citizenship. ”
NATURAL RESOURCE-OUR BUSINESS “Think Locally Act Globally”
VEDANTA - JHARSUGUDA 5 LTPA Aluminium Smelter 1215 MW CPP 12.5 LTPA Aluminium Smelter 2400 MW IPP
MAKING OF ALUMINIUM
ALUMINIUM ELECTROLYSIS CELL
ENERGY CONSERVATION “Neither a campaign nor an initiative It is our habit and culture”
ALUMINIUM – ENERGY INTENSIVE 32% 68% 2% Energy Other Cost 98% Electricity Fuel
ENCON PROJECTS (2011-14) No. Of ENCON Projects 81 Energy Savings 385 (M kWh) Energy Savings 4020 (MT of fuel) INR 112 Saving(Cr.) INR 3 Investment (Cr.) “Small investments and high returns”
MAJOR ENERGY SAVING PROJECTS Energy Savings Sl.No. Title of the Project (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 Reduction of dead pot voltage and crossover 6 8715 voltage . 7 Optimization of Compressor running. 5310 Online addition of pots into circuit by fuse blown 8 2324 technology. 9 HTM heater set point optimization in GAP. 1808 Reduction of the Specific Energy consumption of 10 Wire Rod Mill. 1269 11 Improve Rodding shop availability. 589
MAJOR FUEL SAVING PROJECTS Fuel Savings Sl.No. Title of the project (MT/Annum) Reduction of HFO consumption in 1 3051 Anode Baking Furnace Optimized usage of compressor in 2 34 Metal Transport Vehicle Reduction of diesel consumption in 3 production vehicles by improving 27 engine efficiency Optimization of LPG burner use for 4 15 ingot Casting. “Save Today for a better Tomorrow”
SMALL GROUP ACTIVITIES 2014-15 Rectifier Utility Cast Carbon Potline House War Room • No. Of • No. Of • No. Of • No. Of Projects : 4 Projects : 6 Projects : Projects : 6 • No. Of 21 Projects : 5 • Yearly • Yearly • Yearly Saving : Saving : • Yearly Saving : • Yearly War Room Discussion 355 MWh 4082 Saving : 184 MWh Saving : MWh 13087 3791 • Employees • Employees MWh Project MWh : 10 • Employees : 200 Champions : 8 • Employees • Employees : 120 : 25 Yearly Saving :- 22 M KWh “We value every small Contribution” Asset Optimization Trophy
ENERGY CONSUMPTION TRENDS Total SEC-Smelter (GJ/MT) 59 60 55 54 53.5 52.9 55 50 45 2011-12 2012-13 2013-14 2014-15 TARGET HF0-Kg/MT AC-KWh/MT 14623 HFO-Kg/MT 70 80 14650 64 54 14400 48.2 60 45 14024 14150 40 13806 13818 13900 13566 20 13650 0 13400 2011-12 2012-13 2013-14 2014-15 Target 2011-12 2012-13 2013-14 2014-15 Target “Save What ?? Save a Watt”
ENCON JOURNEY HFO & Stub to Cathode Carbon Slotted 2014 Anode Fuse 2013 Technology GMEA award 2012 Clamp CII Award 2011 Drop ISO 50001 Russian Govt.- Award Certified NECA -1 st Prize 2010 CII Award EnMS Implemented BEE Award Energy Audit by TERI Energy Audit by CII
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
REVIEW STRUCTURE Formation of Energy Cell Energy review structure “Top to Bottom approach”
IT ENABLEMENT MES Online Flash Energy Efficient Capex Energy Impact Report Procurement Assessment “Automation leads to Perfection”
ROAD MAP TOWARDS BENCHMARK Magnetic Field Compensation Of Electrolysis Cells Cathode Modification Of Electrolysis Cells Up-gradation of Pot Control & Feeding System Waste Heat Recovery “Measure to Control - Benchmark to Better” 18
Cathode thode Mo Modi dification ication
CATHODE MODIFICATION 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 Savings/Year – 88 M KWh “Every Unit counts”
Re Reductio duction n of f HFO FO Co Consump nsumption tion
PREHEATING CURVE MODIFICATION Pre Heating Curve Preheating curve modified Initial Final to improve pitch volatile 900 combustion 800 700 Temperature (°C) RESULT 600 • Preheating 500 temperature increased from 740°C to 800°C 400 • HFO injection reduced from 78 to 76 Hrs . 300 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 Hrs
REDUCTION OF FALSE AIR INGRESS Gap between burner stand & Gap covered with packing ring coke The gap between the flue and burner base ,flue hole cover , Effective sealing by Packing thermocouple base had false Coke air intake
REDUCTION OF RADIATION LOSS BEFORE AFTER • Flue Hole Covers were modified to reduce radiation Cover Surface Temp.( ° C) losses 260 • Metallic cylinder and nets were replaced with ceramic 240 258 220 wools and holding plates 200 • Insulation in the new design is farther from heat source 180 • Cast Iron Rings were replaced by refractory rings 160 185 • Redesigned covers surface temperature was lowered 140 by 73°C 120 • Modified covers were Rs.700 cheaper than the original 100 Before After design
REDUCTION OF HFO CONSUMPTION HFO CONSUMPTION KG/MT BAKED ANODE 65 60 55 50 45 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. “Improvement is an Infection”
Re Reductio duction n of f St Stub ub to Ca Carbon rbon mV mV Dr Drop op
REDUCTION OF STUB TO CARBON mV DROP Resistance at the gap filled by Cast Iron between the Steel Stub & Carbon Anode mV Stub Cast Iron Carbon
CAST IRON COMPOSITION Cast Iron Carbon Equivalent 5.10 4.90 4.70 4.50 4.30 4.10 3.90 Cast Iron C.E lsl usl 3.70 3.50 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 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
STUB HOLE DESIGN CHANGE BEFORE AFTER 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
REDUCTION IN STUB TO CARBON mV DROP Stub To Carbon mV Drop 135 125 115 mV 105 95 85 mV 79 75 Reduction in Stub to Carbon mV drop = 66 mV per Pot Savings/Year is 110 M KWh “Every milli Volt Counts”
Re Reductio duction n in n Ca Cast st Ir Iron on Sp Spill illage age
Reduction in Cast Iron Spillage PROBLEM DEFINITION: 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 BENEFITS: Cast iron spillage reduced by 87 ton/month. 450mm Energy saved 0.7 M KWh/Year 12000 Man-Hours saved per year. Total cost savings is Rs. 25 lakhs / year. “Opportunity Everywhere”
Co Cooling ling Fa Fan R n Runn unning ng Ho Hour urs
Baking Furnace Cooling Fans PROBLEM DEFINITION: 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 BENEFITS: Energy consumption from 6912 KWH/day to 5760 KWH/day Energy saving: 0.4 M KWh / Year Cost saving: Rs. 10 lakhs / year “Conserve here to Consume there”
Ene Energy y Re Redu duction ion Bi Billet et Ho Homo mogen genizat zation ion
Energy saving in homogenizing furnace PROBLEM DEFINITION: Power consumption in homogenizing furnace was high at 220KWH/ton. INTERVENTION Replaced Rock wool to Rock wool + Cera wool sandwich BENEFITS Power consumption reduced from 220 KWH/ton to 212 KWH/ton. Energy saved 1 M KWh/ year Cost savings is Rs. 25 lakhs/year. “Kaizen for a Khazana ”
Re Reductio duction n in n ID F ID Fan an Power wer Co Consumptio nsumption
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