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

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 metals and Trust mining group and generate Entrepreneurship superior financial returns. ” Sustainability Our Vision Our DNA “We will be the world’s most admired company that Humble consistently defines the leading standards in our businesses, making our Hungry Smart stakeholders proud to be associated with us. ” 4/29/2015 KEP WORKSHOP

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

Aluminium & Power, Jharsuguda PLANT LOCATION ODISHA INDIA PLANT SITE 4/29/2015 KEP WORKSHOP

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/Nm 3 4/29/2015 KEP WORKSHOP

Aluminium & Power, Jharsuguda IMPLEMENTATION & LEARNINGS ISO 50001 ENERGY MANAGEMENT SYSTEMS 4/29/2015 KEP WORKSHOP

Aluminium & Power, Jharsuguda ENERGY MANAGEMENT TEAM- POWER 4/29/2015 KEP WORKSHOP

Aluminium & Power, Jharsuguda MILESTONES ISO 50001  CPP :  Kick-off ISO 50001:2011 30th Jan 2012  Stage-2 Audit (Certification Audit) 12th - 15th Sept 2012  IPP :  Kick off ISO 50001:2011 30 th Jun 2012  Certification Audit 26 th Feb 2013 to 1 st Mar 2013 4/29/2015 KEP WORKSHOP

Aluminium & Power, Jharsuguda ENCON EFFORTS & BENEFITS SHR = 2442 Kcal/kwh ; APC= 9.66%; SOC = 0.11 ml/kwh CPP 2014-15 SHR = 2337 Kcal/kwh; APC= 8.08%; SOC= 0.38 ml/kwh IPP 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 2010-11 CPP SHR = 2678 Kcal ; APC= 10.14%; SOC= 0.80ml/kwh IPP SHR= 2430 Kcal/kwh; APC= 9.89%; SOC= 1.12 ml/kwh 2012-13 4/29/2015 KEP WORKSHOP

Aluminium & Power, Jharsuguda PROCESS IMPROVEMENT (9X135 MW) 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 4/29/2015 KEP WORKSHOP

Aluminium & Power, Jharsuguda PROCESS IMPROVEMENT (9X135 MW) 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 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 of 1 compressor.  Annual saving- 188.31 MTOE 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 4/29/2015 KEP WORKSHOP

Aluminium & Power, Jharsuguda PROCESS IMPROVEMENT (9X135 MW) 7. Optimization in Electrostatic Precipitator :  The 1 st 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

Aluminium & Power, Jharsuguda PROCESS IMPROVEMENT (4X600 MW) 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 4/29/2015 KEP WORKSHOP

Aluminium & Power, Jharsuguda PROCESS IMPROVEMENT (4X600 MW) 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 4/29/2015 KEP WORKSHOP

Aluminium & Power, Jharsuguda PROCESS IMPROVEMENT (4X600 MW) 5. Reduction of start up time: Very hot Start up 1.60  Six Sigma project implemented to reduce very hot startup 1.50 1.16  Step by step activity/process prepared 1.00  Very hot startup time reduced to 1hr 35min to 1hr 10min 0.50  saving- 63 MTOE 0.00 before after 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 of 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 Reduction in time by increasing furnace temp 4.5 3 5 2.29 4 2 1.52 2.5 3 1 2 0 1 before after before after 4/29/2015 KEP WORKSHOP

Aluminium & Power, Jharsuguda 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 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 4/29/2015 KEP WORKSHOP

Aluminium & Power, Jharsuguda PROCESS IMPROVEMENT (4X600 MW) 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 4/29/2015 KEP WORKSHOP

Aluminium & Power, Jharsuguda TECHNOLOGY IMPROVEMENT (9X135 MW) 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 4/29/2015 KEP WORKSHOP

Aluminium & Power, Jharsuguda TECHNOLOGY IMPROVEMENT (9X135 MW) 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