BEST PRACTICES ON ENERGY SAVINGS SESA STERLITE LTD JHARSUGUDA , - - PowerPoint PPT Presentation

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BEST PRACTICES ON ENERGY SAVINGS SESA STERLITE LTD JHARSUGUDA , - - PowerPoint PPT Presentation

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Aluminium & Power, Jharsuguda BEST PRACTICES ON ENERGY SAVINGS SESA STERLITE LTD JHARSUGUDA , ODISHA Aluminium & Power, Jharsuguda GROUP PHILOSOPHY Our Mission Our Values Excellence Our mission is to be a Growth world-class

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Aluminium & Power, Jharsuguda

SESA STERLITE LTD JHARSUGUDA , ODISHA

BEST PRACTICES ON ENERGY SAVINGS

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Aluminium & Power, Jharsuguda

GROUP PHILOSOPHY

Humble Smart Hungry Our DNA Our Vision “We will be the world’s most admired company that consistently defines the leading standards in our businesses, making

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stakeholders proud to be associated with us.” Our Values Our Mission “Our mission is to be a world-class metals and mining group and generate superior financial returns.”

Growth Trust Sustainability Excellence Entrepreneurship 4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

BUSINESS DIVERSIFIED

→ Sesa Sterlite, a Vedanta Group company is one of the world‘ largest global diversified natural resource company. → FTSE 100 London Stock Exchange listed company. → Operations span across India, Sri Lanka, Africa, South Africa, Europe and Australia.

4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

PLANT LOCATION

INDIA

PLANT SITE 4/29/2015 KEP WORKSHOP

ODISHA

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Aluminium & Power, Jharsuguda

PLANT PROFILE

Capacity of 3615 MW ISO 9001,14001,50001 & OHSAS 18001 Certified Water Source – Hirakud Reservoir Coal Source- Mahanadi Coal Fields High Concentration Slurry Disposal Hybrid ESP with SPM level < 40mg/Nm3

4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

IMPLEMENTATION & LEARNINGS ISO 50001 ENERGY MANAGEMENT SYSTEMS

4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

ENERGY MANAGEMENT TEAM- POWER

4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

 CPP :  Kick-off ISO 50001:2011 30th Jan 2012  Stage-2 Audit (Certification Audit) 12th - 15th Sept 2012  IPP :  Kick off ISO 50001:2011 30th Jun 2012  Certification Audit 26th Feb 2013 to 1st Mar 2013

MILESTONES ISO 50001

4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

ENCON EFFORTS & BENEFITS

Implementation of Total Quality Mngt. Culture Implementation of New Technologies Implementation of IT Enablement in procuring Energy Efficient Equipments Improvement in Process & Operational Practices Development and Implementation of Innovative and Breakthrough Energy Efficiency Improvement Projects. Daily Monitoring of Specific Consumptions & Deviation Analysis Energy Improvement Projects is linked to Individual KRA’s Energy Audit by CII in June’11 & ISO 50001 implementation & certification in the year of 2012

SHR = 2442 Kcal/kwh ; APC= 9.66%; SOC = 0.11 ml/kwh

2014-15

2010-11 SHR = 2678 Kcal ; APC= 10.14%; SOC= 0.80ml/kwh

4/29/2015 KEP WORKSHOP

SHR = 2337 Kcal/kwh; APC= 8.08%; SOC= 0.38 ml/kwh IPP CPP SHR= 2430 Kcal/kwh; APC= 9.89%; SOC= 1.12 ml/kwh IPP CPP 2012-13

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Aluminium & Power, Jharsuguda

  • 1. Selective Soot-blowing:
  • Optimized need based soot-blowing resulting in flue gas exhaust temperature from

141°C to 137°C and reduction in super-heater spray by 2% that is 8 T/hrs.

  • Annual saving- 5.82 MTOE
  • 2. Stoppage of purging of HFO guns:
  • Purging of HFO guns on regular basis are stopped
  • Annual saving- 35.93 MTOE
  • 3. Optimization of key Process Parameters:
  • Operational optimization by maintaining the technical parameters like Main-steam

pressure, main-steam temperature , etc. near to design value.

  • Annual saving- 3.17 MTOE

PROCESS IMPROVEMENT (9X135 MW)

4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

  • 6. Optimized running of Dry Ash conveying system:
  • Running of Dry-Ash conveying system in level mode from timer mode resulting in

stoppage of 1 compressor.

  • Annual saving- 188.31 MTOE
  • 5. Optimized use of Compressor:
  • Stoppage of Dryers in Service Air system (6 nos.)
  • Arresting of leakages and rectification of intake valve passing resulting in stoppage
  • f 1 compressor.
  • Annual saving- 188.31 MTOE
  • 4. Cooling Tower fan door plugging:
  • Plugging of the holes of Cooling Tower fans, hence reduction in fan loading via

excess air leakage and improvement in vacuum.

  • Annual saving- 22.14 MTOE

4/29/2015 KEP WORKSHOP

PROCESS IMPROVEMENT (9X135 MW)

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Aluminium & Power, Jharsuguda

  • 7. Optimization in Electrostatic Precipitator :
  • The 1st Field ESP hopper heaters are switched off during normal running of the

units.

  • Each hopper consist of 2 heaters of 3Kw each.
  • Annual saving- 72.31 MTOE
  • 8. Improvement in Belt utilization:
  • Improvement in Belt utilization by rectifying the track hopper, ILMS (In-line

magnetic separator and replacement of existing conveyor with the new conveyor.

  • Annual saving- 65.34 MTOE
  • 9. Operational Optimization of Mills Lube-Oil pump:
  • Stoppage of stand-by Mills Lube-Oil pump
  • Annual saving- 45.19 MTOE

4/29/2015 KEP WORKSHOP

PROCESS IMPROVEMENT (9X135 MW)

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Aluminium & Power, Jharsuguda

PROCESS IMPROVEMENT (4X600 MW)

4/29/2015 KEP WORKSHOP

  • 1. Increase Reheater temp(528°C to 538°C):
  • Daily Monitoring HRD sheet
  • SADC checking(S/D)
  • Burner tilt operation
  • Increase in HRH temp from 528 to 538°C
  • Unit heat rate improved by 2 kcal/kwh
  • Annual saving- 1653 MTOE
  • 2. Identification and plugging of air ingress points in flue gas ducts
  • Flue gas, air duct leakage detection resulting in ID FAN Avg. current reduced from 246 A to

234 A. (power reduce by 0.5 MW) &.083 % APC reduction

  • Annual saving- 376 MTOE
  • 3. PA Fan power reduction by arresting air leakage
  • Seal air leakage detection and PA hot air and cold air to mill leakage detection in U#2

resulting in PA FAN A- Current reduced from 106 A to 86 A and PA FAN B-108 A to 82 A (Power reduced by 0.95 MW) APC reduced by 0.158 %.

  • Annual saving- 715 MTOE
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Aluminium & Power, Jharsuguda

4/29/2015 KEP WORKSHOP

  • 4. Optimization of idle running hours of drives:
  • Stopping of One CW pump as per circulating water inlet and outlet

temperature.

  • Annual Saving: 393 MTOE/Unit
  • Stopping of one Vacuum pump as per condenser Vacuum
  • Annual Saving : 216 MTOE/Unit
  • Stopping of DP pump for makeup in condenser.
  • Annual Saving - 203 MTOE/Unit
  • Implementation of shutdown checklist to Stop the running equipment
  • Annual Saving - 144 MTOE/Unit
  • During Unit Startup use TDBFP instead of MDBFP
  • Annual Saving - 120 MTOE/Unit
  • Stopping of 1 seal air fan(250 kw) by arresting seal air leakages
  • Annual Saving: 41 MTOE/Unit

PROCESS IMPROVEMENT (4X600 MW)

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Aluminium & Power, Jharsuguda

4/29/2015 KEP WORKSHOP

  • 5. Reduction of start up time:
  • Six Sigma project implemented to reduce very hot startup
  • Step by step activity/process prepared
  • Very hot startup time reduced to 1hr 35min to 1hr 10min
  • saving- 63 MTOE

1.60 1.16

0.00 0.50 1.00 1.50 before after

Very hot Start up

PROCESS IMPROVEMENT (4X600 MW)

  • 6. Reduction of startup time by Deaerator pegging in boiler and turbine preheating
  • Boiler feed water temp increased to 121°C (earlier 50°C) by deaerator pegging. Which

raised the furnace temp to 97°C (earlier temp was 40°C).Time reduced to 20 min

  • During turbine preheating ,HP inner /outer casing temp was raised to 204 /192° C instead
  • f 150°C ,which has reduced the time of heat soak by 2 hrs.
  • SAVING : reduction in oil consumption during startup to 121 MTOE

Reduction in time by heat soaking

4.5 2.5 1 2 3 4 5 before after 2.29 1.52 1 2 3 before after

Reduction in time by increasing furnace temp

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Aluminium & Power, Jharsuguda

4/29/2015 KEP WORKSHOP

8.Reducing the output voltage of lighting transformer

  • No of taps were reduced in lighting transformer with a reduction in voltage from 432 volts to

415 volts resulted in power saving of 30.2 Kwhr per day

  • Annual Saving: 1 MTOE

9.Increasing ash utilization by disposing Ash through trucks

  • Reduction of ash conveying from transfer silo to terminal silo, as D-pump ash conveying

capacity averagely 260tns/hr. Stopped one compressor.

  • Geho pump dispose 260T of ash per hour. As 4,500T of ash transported through trucks,

per month 18 hours of Geho running hour reduced.

  • Saving of 10654 kwhr power per month and specific power: 0.05 Kwhr/MT
  • Annual saving: 7 MTOE

PROCESS IMPROVEMENT (4X600 MW)

  • 7. Reduction of Number of Trips :
  • Identify the root cause of all unit outages
  • Implement recommendation of Trip analysis
  • saving- 150 MTOE/Unit
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Aluminium & Power, Jharsuguda

4/29/2015 KEP WORKSHOP

10.Increasing CHP conveyor belt utilization

  • Increasing coal conveyor belt utilization from 50 % to 60 % (from 1500 TPH to 1980 TPH)

to minimize the power consumption with saving of 922 MWhr

  • Annual Saving:97 MTOE
  • 11. Reduction of Rake Turn Around Time
  • Elimination of idle running time of stream and compressor with a saving of 263 MWhr
  • Annual Saving: 22 MTOE

PROCESS IMPROVEMENT (4X600 MW)

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Aluminium & Power, Jharsuguda

  • 1. Condenser Cleaning (Jet, bullet & chemical):
  • Condenser Jet cleaning=1 unit; Bullet cleaning=4 Units; Chemical cleaning=1 unit
  • Average improvement of 20 kCal/kWh/Unit/Kpa in Heat Rate.
  • Annual saving- 148.74 MTOE

BEFORE AFTER

TECHNOLOGY IMPROVEMENT (9X135 MW)

4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

  • 2. Air Preheater seal and basket replacement :
  • Air Preheater Baskets and soft touch seals replaced resulting in Improvement of

boiler efficiency by 0.5%

  • Reduction in Primary Air Fan (PA) loading of 103 Kwh
  • Annual Saving: 620.50 MTOE

BEFORE AFTER

4/29/2015 KEP WORKSHOP

TECHNOLOGY IMPROVEMENT (9X135 MW)

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Aluminium & Power, Jharsuguda

  • 3. CT Fans Blades Replacement :
  • For each unit, 5 CT cells are designed.
  • Weight of GRP blades is more than FRP blades.
  • Total 13 nos. of GRP blades replaced with FRP blades.
  • Average Savings : 234.70 MTOE.

BEFORE AFTER

4/29/2015 KEP WORKSHOP

TECHNOLOGY IMPROVEMENT (9X135 MW)

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Aluminium & Power, Jharsuguda

  • 4. Replacement of Old Chrome rollers with New

Sinter Cast Rollers & Liners

  • Rollers & Liners are replaced by New Sinter

Cast Rollers

  • Reduction in Mill power consumption by 30 KW.
  • Running hours increased from 6000 to 18000

hrs.

  • Savings : 17.54 MTOE.

BEFORE

4/29/2015 KEP WORKSHOP

TECHNOLOGY IMPROVEMENT (9X135 MW)

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Aluminium & Power, Jharsuguda

  • 5. CW pump Impeller coating:
  • CW pump impellers coated with

Brush able coating

  • Reduction in CW pump loading

by 68 kw

  • Annual Saving: 45.19 MTOE.

4/29/2015 KEP WORKSHOP

TECHNOLOGY IMPROVEMENT (9X135 MW)

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Aluminium & Power, Jharsuguda

  • 6. Ultrafilteration Installation to Reduce DM Water Consumption:
  • Installation of Ultrafiltration System to reduce the colloidal silica in

Demineralized (DM) water.

  • Reduction of Blow down losses by 80% & heat losses.
  • Annual Saving: Rs. 213.62 Million.

Ultra-filtration System

4/29/2015 KEP WORKSHOP

TECHNOLOGY IMPROVEMENT (9X135 MW)

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Aluminium & Power, Jharsuguda

  • 7. Modification of Fly Ash Conveying System:
  • Due to modification the consumption of compressed service air reduced

resulting in stoppage of 2 compressors.

  • Each of the units was provided with a separate air vessel to compensate the

fluctuations.

  • The ash collection vessel size was increased for ESP 3rd field and same was

placed in 4th field

  • Annual Savings: 376.61 MTOE

BEFORE AFTER

4/29/2015 KEP WORKSHOP

TECHNOLOGY IMPROVEMENT (9X135 MW)

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Aluminium & Power, Jharsuguda

  • Earlier Turbine hall & compressors house consisted of 72 & 16 electrics fans

respectively.

  • Each fan rated capacity 3 kw.
  • Electric fans are replaced by Eco ventilators (224+28) in TG Hall as well as in

Compressor house.

  • Energy savings : 199.39 MTOE
  • 8. Installation of Eco Ventilators :

4/29/2015 KEP WORKSHOP

TECHNOLOGY IMPROVEMENT (9X135 MW)

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Aluminium & Power, Jharsuguda

Project : Utilization of Waste Water :Effluent Treatment Plant - 2 (ETP) Commissioning. Before:

  • More than 4000m3/day of waste

water was discharged out of the plant

  • Specific water consumption was

high After:

  • Waste water management by

treatment in ETP

  • Zero discharge of water out of

plant

  • Specific water consumption is

reduced

CPP Synergy Office CPP Switchyard CW Pump Area CT Fans Area

4/29/2015 KEP WORKSHOP

TECHNOLOGY IMPROVEMENT (9X135 MW)

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Aluminium & Power, Jharsuguda

Project : ESP Bag Filter Retrofitting.

Before:

  • Designed ESP had 5 fields
  • Ammonia dozing was in process
  • Avg. SPM was more than 100

mg/Nm3 After:

  • Last 2 fields replaced with Bag filter
  • Ammonia dozing stopped
  • Existing Ash Conveying system is

modified

  • Avg. SPM < 30mg/Nm3

BEFORE AFTER BEFORE

4/29/2015 KEP WORKSHOP

TECHNOLOGY IMPROVEMENT (9X135 MW)

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Aluminium & Power, Jharsuguda

TECHNOLOGY IMPROVEMENT (4X600 MW)

AFTER BEFORE

4/29/2015 KEP WORKSHOP

  • 3. Reduction of power in CEP after removal of one stage
  • Removal of CEP stage in order to compensate energy loss due to throttling of deaerator

level control valve resulting in CEP Pump-Current reduced from 123A to 92 A. (0.45 MW power reduced & 0.075 % APC

  • Annual saving- 167 MTOE
  • 1. Boiler Modification(LTSH,ECO,RH):
  • Reduced the surface are of LTSH tubes and increase the contact area of economizer

bank which resulted in SH spray reduction and increase in feed water temp.

  • The modification includes
  • LTRH zone curtailment by 120 tubes
  • Installation of riffled tubes over exposed furnace water wall tubes
  • LTSH tube curtailment by 1 bank
  • Economizer zone extension by 1bank.
  • Annual saving- 4745 MTOE
  • 2. Power reduction in CW pump due to speed reduction
  • Addition of no of rotor poles from 16 to 18 in CW pump in U#4 for speed reduction saving-

0.233 % APC CWP current reduced from 290 AMPS to 235 AMPS and 1.4 MW saving in power consumption

  • Annual Saving: 520 MTOE
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Aluminium & Power, Jharsuguda

AFTER BEFORE

4/29/2015 KEP WORKSHOP

  • 6. VFD installation in BA slurry pump
  • Installation of variable frequency drive in bottom ash slurry pump in U#1,U#2 with a saving
  • f 68 Kwhr
  • Annual Saving: 45 MTOE

Before After

RPM 990 700-750 KW 135.5 67.3 KVA 160.1 68.4 KWH 3313 1152 KVAH 3881 1168

TECHNOLOGY IMPROVEMENT (4X600 MW)

  • 7. Indigenization of ID fan motor
  • U#1 ID FAN 1A motor replaced with CGL make with a net saving per day with a new motor

@ 60kw. In addition to this there is a saving due to stoppage of 1 cooling fan having power consumption 7.5 kw and one lube oil pump having power consumption 1.1 kw

  • Annual Saving: 9 MTOE
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Aluminium & Power, Jharsuguda

AFTER BEFORE

4/29/2015 KEP WORKSHOP

9.Use of induction lamp in mill coal feeder

  • Incandescent lamp of 40 w were replaced by induction lamp of 18 Watt in all mill coal

feeders of U#1,U#2 and U#3 with a saving of 528 Kwhr per feeder per day

  • Annual Saving: 1 MTOE

TECHNOLOGY IMPROVEMENT (4X600 MW)

  • 8. Implementation of auto timer in lighting system
  • Earlier for lighting there is no time limit .We have installed timer for illumination in different

area with a saving of 62 kwhr

  • Annual Saving: 1.95 MTOE

10.Installation of EPIC-3 controller in ESP field

  • In U#2 ESP field controller from Dalian Chinese make to EPIC-3 controller with a flexibility
  • f changing field charge ratio resulted in saving of 240 kwhr per day
  • Annual Saving: 1 MTOE
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Aluminium & Power, Jharsuguda

AFTER BEFORE

4/29/2015 KEP WORKSHOP

  • 11. Mill Hot air gate modification and mill lube oil system modification :
  • Mill Hot air gate modification and mill lube oil system modification in all 4 units resulting in

reduction of oil consumption by increasing equipment availability which is equivalent to decrease in SOC by 0.2 ml/Kwhr

  • Annual saving- 159 MTOE

Mill HAG Modification Mill Lub oil system modification

TECHNOLOGY IMPROVEMENT (4X600 MW)

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Aluminium & Power, Jharsuguda

DAILY MONITORING

4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

DAILY MONITORING

Monitoring system

  • Integrated Energy Meters are installed for HT &

LT motors and configured in DCS. Meters used for all measurements are calibrated as per ISO Standards

  • Related Process parameter are displayed on

the DCS screen.

  • All relevant energy data is captured from these

resources at regular intervals by PDHR data.

4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

TQM CULTURE

5S Certified

  • 5S structure, zones created & effective audit is in place.
  • 5S Awareness sessions are conducted for direct & indirect

employees

  • 6 zones and 24 Subzones
  • Total employee engagement in 5S is 128 direct & 450

indirect Quality Circle/ Lean Quality Circles

  • Awareness training completed for 360 employees

(SSL & Service provider)

  • Total 20 QC teams formed Including SSL employee

and Service providers

  • Total 140 SSL employees and service providers are

engaged in this initiative Sig Sigma

  • Wave-3 has 9 top priority projects driven by 55 employees
  • 4 Team Leaders qualify for Black Belt Certification and 24

Team Members would qualify for Yellow Belt Certification. 4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

Total Savings: 13077 MTOE

Total Savings: 13077 MTOE CPP : 2482.82 MTOE IPP : 10595 MTOE

ENCON SUMMARY IN 3 YEARS

4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

AWARDS & RECOGNITION

7th India Power Award 2014 Engineering Excellence Awards 2014 Excellent Energy Efficient Unit 2014 Top Plant Award -2014 4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

AWARDS & RECOGNITION

6th India Power Award 2013 Engineering Excellence Awards 2013 Excellent Energy Efficient Unit 2013 National Energy Conservation Award-2012 National Energy Conservation Award-2011 4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

THANK YOU

4/29/2015 KEP WORKSHOP