Team Hindalco Welcomes You All Energy Efficiency Activities Through - - PowerPoint PPT Presentation

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Team Hindalco Welcomes You All Energy Efficiency Activities Through - - PowerPoint PPT Presentation

Nov 03, 2023 447 likes •1.14k views

Team Hindalco Welcomes You All Energy Efficiency Activities Through Small Groups 1 Team Members 1. Mr. Vivek Agrawal 2. Mr. Anuj Verma 3. Mr. Vivek Kumar 2 Aspect of Energy Saving Ensuring Energy Security. Climate Change

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SLIDE 1

Energy Efficiency Activities Through Small Groups

1

Team Hindalco Welcomes You All

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SLIDE 2

Team Members

1.

  • Mr. Vivek Agrawal

2.

  • Mr. Anuj Verma

3.

  • Mr. Vivek Kumar

2

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SLIDE 3

 Ensuring Energy Security.  Climate Change Concerns.  Statutory requirement like PAT , RPO etc.

3

Aspect of Energy Saving

 By Enhancing energy efficiency.  By Energy conservation

Methodology

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SLIDE 4

How is it possible to involve every person of Industry ?

In this system , we ensure

the participation of each individual for intensive involvement.

4

By small group

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SLIDE 5

APEX COMMITTEE WCM SECRETARIAT SETUP IN ALL PLANTS / DEPLOYMENT COMMITTEES PLANT SUB COMMITTEES SMALL GROUPS (TEAMS) Directly linked to activities

  • r machine

AREA COMMITTEES FOR SECTIONS

Organization Structure to involve each individual for improvement

Level 4 Level 3 Level 2 Level 1 5

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SLIDE 6

Energy Balance sheet

6

World Scenario:

  • Coal

: Reserve for 109 years

  • Oil

: Reserve for 52.9 years

  • Gas

: Reserve for 55.7 years

Indian Scenario:

  • Coal

: Reserve for 100 years (10% of world production)

  • Oil

: Reserve for 17.5 years (0.3% of world production)

  • Gas

: Reserve for 33.1 years (0.7% of world production) Source : BP Statistical Review of World - 2013

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SLIDE 7

7

In Hindalco all these small group , TQM , TPM etc related activities are being implemented under WCM umbrella. No. of Small Groups : 454 Involvement : 100% Members per small group : 12 to 20 Philosophy

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SLIDE 8

Number of Small Group Renukoot

50 100 150 200 250

No

Small Group 79 206 77 15 28 49 Alumina Reduction Fabrication Cogen. Utilities & Services Commercial

Total No of Small Group - 454 Hindalco – Renukoot

8

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SLIDE 9

9

Case study : 1

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SLIDE 10

10

Selected problem

Sump pumps in caustic recovery pit always running in Heat Interchange Department area, while there is no level in the pit.

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SLIDE 11

Wagon Tippler Hammer Mill Slurry Mix Clarification

Red Mud Disposal Yard

Precipitation

Drum Filter Calcination

(Pregnant Liquor) HRD Under Flow

Spent Liquor

HRD Hydrate (Al2O3.3H2O) Red Mud

Al2O3 (ALUMINA)

Bauxite from Mines Digestion Evaporation Clarification Compressor

11

Process Flow diagram

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SLIDE 12

These pumps have been installed in Alumina plant to pump the caustic from pit to the process. Since these pumps are operated manually therefore these pumps were running continuously after pit being emptied. Hence we lose electrical energy.

Therefore we have chosen this project to save electrical energy.

12

Problem Identification

Area Hosing Liquor To Process

Switch Manually Operated

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SLIDE 13

Before Improvement / Kaizen

13

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SLIDE 14

 Stress in work place  Unavailability of Equipment

 Same Work Again  Maintenance of Equipment

14

Effect of Problem

Loss of Electrical Energy

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SLIDE 15

Target

To develop a process to stop idle running hours of sump pumps.

15

To save Electrical Energy

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SLIDE 16

No. Activity Week

01 02 03 04 05 6 07 08 09 10 11 12

1.

Selection of problem

2.

Identification of problem

3.

Analysis of the problem

4.

Identification of Basic reason

5.

Development of Solution

6.

Implementation Trials

7.

Review & Followup

Target

Mile stone chart

Q.C. – Suprabhat Deptt – Alumina Elect.Maint. Co-ordinator – R.S.GAUTAM Facilitator – A.P.Pandey Members HIRA LAL A.K.SINGH J.P.SINGH S.K.SHUKLA B.R.VERMA K D Yadav T.R.YADAV K.SINGH ANUJ VERMA R.P.GUPTA Project :~To Avoid idle running of caustic recovery sump pump

Reasons for selection : Availability of Equipment

Project No. – 1 Start -JAN - 2014 Completed –MAR-2014 Meeting – Every Friday Time :~ 4:00 pm – 5:00 pm

16

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SLIDE 17

Continuously

running of Caustic recovery sump pumps

Operator (Man) Materials

Machine Method

Pump was operated manually by

  • perator

Pumps tripping, & breakdown

Wastage of Energy Idle running of sump pump

Operator had lot of jobs to be done at the same time, he may forgot to stop Pump takes over current & vibration problems

17

Level sensor & hour meter were not installed since commissioning No measuring

  • f Running hrs
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SLIDE 18

Type

Defects

Freq. %

Contribution

A.

No installation of level sensor in caustic recovery pit, hence idle running hours of sump pumps.

7 70 % B.

Problem in a cable of sump pump

2 20% C.

Other reasons

1 10 %

Jan’14 to Mar’14

Reason & Contribution

18

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SLIDE 19

Pareto- Diagram

50 100 90

Problems

B C A

Frequency

40 70 20 10 30 60 80

19

Idle Running Hrs

Cable Problem Others

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SLIDE 20

20

Small Group members have given following suggestions during brain storming session

Brain Storming

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SLIDE 21

To run sump pump only twice in a shift and stop after empty of pit.

X

Possibility of Human error.

21

Suggestion # 1

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SLIDE 22

X

To replace caustic sump pump by air pump to empty the pit.

Use of compress air is also costly & wastage of energy.

22

Suggestion # 2

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SLIDE 23

To install a level sensor in caustic recovery pit which works on auto mode. This is a good suggestion and approved by top management.

23

Suggestion # 3

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SLIDE 24

We found that the level sensor works automatically and it makes the pump off when there is no level in the pit

Suggestion become successful

DO Wiring has been done in the panel according to the drawing.

24

  • 1. It is informed to section in

charge & operation to implement the idea. 2.We have modified the drawing to modify the circuit.

PDCA Cycle

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SLIDE 25

In-house built Sensor Auto/Manual ON/OFF Controller

After Implementation

25

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SLIDE 26

S.No.

Suggestion Implementation

1

Earlier idle running hours

  • f sump pumps was on

higher side It does not happen after implementation

2

There was a loss of energy due to idle running hours of sump pumps There is no loss of energy after installation of level sensor.

3

Earlier Electrical Maintenance work force engagement was more in this case There is no problem today.

26

Comparative study & Effects

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SLIDE 27

27

Comparative Study Idle Running Hrs

98.5% Reduction

12

0.17

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SLIDE 28

28

Comparative Study Energy Consumption

98.58% Reduction in Energy

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SLIDE 29

Intangible Gain

29

Ease working Increase in self confidence Release from mental stress. Development of team spirit Safe & Healthy environment

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SLIDE 30

Direct profit

Sub : Energy Saving by providing Level sensor in caustic recovery sump pump

A

Energy Saving

S/ No.

Details UOM Value Remarks

1

Power Consumption of 6 nos caustic recovery sump pumps (5 x 5 )+ (1x20) = 45 HP (Rated Power) Measured power in KW 36.90

  • 1. New caustic recovery sump pump. (Near HID Gate)
  • 2. TT# 1 West end recovery sump pump.
  • 3. TT# 2 East end recovery sump pump.
  • 4. Old header East end in caustic unloading area.
  • 5. Old header West end in caustic unloading area.
  • 6. New header East end in caustic unloading area.

7.Evaporation # 3 area caustic recovery sump pump. 8.Filter Press Area caustic recovery sump pump.

2

Recovery sump pump running hours per days Hr. 12

3

Sump pumps Running days Days 200

4

Energy Consumed per annum for 6 nos.recovery sump pumps KWH / Annum 88,560 AFTER LEVEL SENSOR INSTALLTION

5

Sump Pump Motor running hour per days Hr. 0.17 10 Minutes

6

Sump pumps Running days Days 200

7

Energy Consumed per annum for 6 nos recovery sump pumps. KWH / Annum 1,225

8

Total Energy Saving after the installation of 6 nos Level sensor for 6 nos recovery sump pump per Annum KWH / Annum 87335

9

Power Saving KW 11

10

Annual Saving Rs. 243,664 Cost of Electrical Energy @ Rs2.79/unit (KWH)

B

Repairing cost Saving

1

Repairing cost of Pump Rs. 5000

2

Life of pump Days 15 Pump failure starting from October'13.

3
  • Nos. of pump

Nos. 8

4

Annual Saving Rs. 240000 We have consider only 3 months cost of repairing. TOTAL SAVING 483,664

30

Electrical energy saved : 87335 kWh / year

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SLIDE 31

31

Case study : 2

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SLIDE 32

32

boLDr no6 ke 4uk6e toD>ne ke dOran Stemal hone vale Compressed Air ke pt ko smaPt krna |

smSya pircy

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SLIDE 33

33

yhI smSya hI Kyo& ?

 Kyo&ik sme& Compressed

Air ka pyog hota hE ijsme&

is 10 – 20% Wja hI p/yog layk rhtI hE =eq Wja hI4 v Aavaj ke p me& nQ4 ho jatI hE |

Kyo&ik..

Noise : 105 DB

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SLIDE 34

Heat Loss 60% Delivered Compressed Air Power Consumed by Compressor Moisture

Dist ribu tion

Treatment Generation

Sankey Diagram for Compressed Air System

Approximately 10% gets to the point of use!! Useful Energy 10 - 15% 34

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SLIDE 35

Raw energy to compressed Air conversion process Coal (100 MT)

Boiler ( 85%)

Turbine

Generator ( Equi to 35 ton ) Transformer Sub Station / Transformer

Sub Station at Receiver end then distribution transformer

User End (Equi. to 27 Ton)

In Air Compressor - ( Utilization 15% -

  • Equi. to 4.1 Ton)

35 35% Efficiency Cascade efficiency : 77%

X

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SLIDE 36

36

Pot room Over view

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SLIDE 37

37

Pot Sectional View

ALUMINA HOPPER

ANODE (+) ANODE (+) MOLTEN CRYOLITE BATH MOLTEN ALUMINIUM

CATHODE BLOCK (-)

POINT FEEDERS SiC BRICKS DIATHERM 23 INSULATION BRICKS CATHODE BUS BAR COLLECTOR BAR POT COVERS ALUMINA INSULATION FROZEN BATH CRUST TOE PLATE MONOLITHIC PASTE LINING DENSE FIRE BRICKS

2 AI2O3 + 3 C 4 AI + 3 CO2

ANODE RING BUS CALCIUM SILICATE INSULATION MOLTEN METAL

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SLIDE 38

38

Pot Baking

Anode

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SLIDE 39

39

  • pa4 me& lge noD i=D\yUl ke

Anusar bdle jate hE& | pa4 se inkle noD wpyog ke dOran km ho jate hE | ijNhe boLDr khte h&E |

Process Description

Anode

  • Aeostn hm 48 boLDr p/itidn mEnuAl toD>te e |
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SLIDE 40

40

 ijsko hm Apne shyogI Pla&4 raiD&g =ap me& -ej dete hE& jha& wse toD>kr kabn Pla&4 me& -ej idya jata hE | kabn Pla&4 ke bal iml me& wse pIs kr pun p/yog hetu tEyar ikya jata hE |

Process Description

Cu-Bar

Stiffener

130

 noD ke tEyar hone ke bad pun wse

pa4la:n me& -eja jata hE taik noD sei4&g ke dOran bdla ja ske |

Recycle & Reuse

 raiD&g m me& p/itidn Aeostn 2300 noD ka inma8 ikya jata hE |

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SLIDE 41

41

raiD&g =ap me& lgI m=In kI ilim4e=n ke kar8 Ai0ktm  &c tk ke boLDr hI toDe> ja skte h&E | Agr iksI kar8v= bD>e saj ka boLDr Aa jay to wse kevl mEnuAl bDe> hEmr ya jEk hEmr kI mdd se hI toD>ne ka kma{a ivkLp a | Problem Description

Anode

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SLIDE 42

42

Problem Data: (Boulder Breaking Details) irka6 ke Anusar ip2le salo& me& boLDr toD>ne ka ivvr8 s p/kar hE 

vq 4n boLDr

2010 2213 2011 2285 2012 2610 2013 2452

Problem Description Aeost p/it vq 2390 Aeost p/it mah 200

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SLIDE 43

43

Methodology Used

Brain Storming

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SLIDE 44

44

phla suzav Aaya ik Kyo& n raiD&g m me& hI k bD>I b/e&ikg iDvas lga: jay | prNtu Jyada cIla hone kI vjh se se AmaNy ikya gya |

Development of Solution

X

suzav n1

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SLIDE 45

45

dUsra suzav Aaya ik Kyo& n bD>e saj ka jEk hEmr mga kr wsse boL6r ko toD>a jay | pr bD>e jEk hEmr kI hENDil&g kaI mui+kl hotI At se -I AmaNy ikya gya |

X

Development of Solution

suzav n2

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SLIDE 46

46

At tIsra suzav Aaya ik Kyo& n boLDr b/eik&g ke il k Alg po4ebl be/ik&g iDvas lga: jay | sI suzav pr hmare gup ne kay krne ka in8y ikya |

Development of Solution

suzav n3

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SLIDE 47

47

Challenges  m=In kI iDjan krna |  haD^oilk jEk kI ByvSa krna |  shI b/eik&g 4Ul ka inma8 krna |  shI spo4 v bes ka inma8 |

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SLIDE 48

48

Development of Solution

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SLIDE 49

49

Plan

hmarI 4Im ne ske il mekeinkl iv-ag kI mdd se be/ik&g iDvas ko lgane ka in*ay ilya | s be/ik&g iDvas me& k mo4I ipn kI mdd se boLDr ko toD>ne ka p/iv0an a |

Development of Solution

Hyd Jack 50MT Cap

Bolder 3” Pin

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SLIDE 50

50

Development of Solution

Do

k mjbUt bes ka inma8 ikya gya ijs pr r kr hm boLDr ko toD> ske& |

Groove in center of base for easy breaking

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SLIDE 51

51

  • jEk ko hoLD rne ke il

k mjbUt spo4 ka inma8 ikya gya |

Do

Jack Holding Support

Development of Solution

  • k mjbUt leg ka inma8

ikya gya ijs pr hm jEk spo4 ko lga ske&& |

Leg

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SLIDE 52

52

Development of Solution

Ab hme& k ha:D^ailk pMp kI Aav+ykta I | jo s&yogv+a hmare pas wplB0 -I a |

Do

pMp ko kneK4 krke 4^ayl ilya gya | pMp ke sa jEk shI trIke se kam kr rha a |

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SLIDE 53

53

Check

Hydraulic Jack

Development of Solution

  • jEk ko hoLD krke dea

gya, hoiLD&g 5Ik I |

  • lg-g 350 iklog/am ke

boLDr ko rkr cek ikya gya, iblkul shI jgh pr boLDr se4 huAa |

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SLIDE 54

54

ACT

Ab be/ik&g ipn kI Aav+ykta I | hmne  &c mo4e ipn ka inma8 kr jEk pr lgaya AOr clakr cek ikya |

Development of Solution

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SLIDE 55

55

Check

prNtu 4^ayl ke dOran hmne paya ik boLDr to 4U4a hI nhI AOr ipn -I beND ho gya | hmne jha se =uAat ikya a pun hm vhI& phuc gye |

Ab hmne Apne iDja:n Aais se sMpk ikya v wnke idye slah ko ApnI bna: g: m=In me& lagU ikya |

Hyd Jack 50MT Cap Boulder 3” Pin

Development of Solution

X

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SLIDE 56

56

Development of Solution

ACT

ir sI m=In me& k A-UtpUv pirvtn ikya gya | ipn kI jgh Pls mak Da: bna kr lgaya gya ta jEk -I 50 4n kI jgh 100 4n xmta ka lgaya gya |

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SLIDE 57

57

hmne cek krke paya ik Ab m=In boLDr ko AasanI se toD> rhI I |

Check

Development of Solution

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SLIDE 58

58

Comparative Study

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SLIDE 59

59

BEFORE AFTER

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SLIDE 60

60

Comparative Study k/.s sma0an ke pUv sma0an ke bad

1 Compressed Air ka Stemal

hota a |

Compressed Air ka Stemal

iblkul bNd ho gya hE |

2

Pahle boLDr b/eik&g ke dOran Aavaj bhut Jyada I | Ab nhI hE |

3

hEmr ya jEk hEmr cla kr boLDr toD>na pD>ta a | Ab s Are&jme&4 ko lgane se jEk hEmr clane kI Aav+ykta nhI |

4.

smy v& [am Ai0k lgta a | Ab nhI& lgta hE |

5.

gmI v 6S4 me& kam krna p6>ta a | Ab kam nhI& krna p6>ta hE |

6.

du34na kI s&-avna I | Ab ibLkul nhI& hE |

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SLIDE 61

61

9.53 0.71

2 4 6 8 10 Lacs Before After

Energy Cost / year

Results

92% Reduction

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SLIDE 62

62

60 0.75

10 20 30 40 50 60 Minutes Before After

Time to attend Break Bolder

Results

99% Reduction

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SLIDE 63

63

324000 24506

50000 100000 150000 200000 250000 300000 350000 KWH/Year Before After

Energy Consumption KWH / Year

Results

Energy Saving

  • f 89.2 MTOE

per year

Electrical energy saved : 0.3 million kWh / year

92% Reduction

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SLIDE 64

64

Tangible Gain

jEk hEmr se boNDr ko n to6ne kI vjh se...  irya kI DiS4&g smaPt |  Naayj levl Dawn |

No use of compressed Air

Investment – Rs.30000/ -

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SLIDE 65

65

 kay me& AasanI |  AaTm bl me& b<i |  tnav muKt kay |  4Im _aavna ka ivkas |

In- Tangible Gain

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SLIDE 66

Yr 1800 Yr 2070 Year 1900 Year 2000

Year 2015

It is never too late to practice energy modesty and efficiency otherwise…….

66

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SLIDE 67

67