Team Hindalco Welcomes You All Hindalco Industries Limited, - - PowerPoint PPT Presentation

Team Hindalco Welcomes You All

Hindalco Industries Limited, Renukoot

Team Member

1.

• Mr. Anuj Kumar Verma

2.

• Mr. Vivek Agrawal

Hindalco Industries Limited, Renukoot

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Aspect of Energy Saving



Ensuring Energy Security.



Climate Change Concerns.



Statutory requirement like PAT , RPO etc.

Methodology

 By Enhancing Energy Efficiency.  By Energy Conservation

Hindalco Industries Limited, Renukoot

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To increase steam economy of Evaporation Unit II by 0.5 T/T.

Target Project

Hindalco Industries Limited, Renukoot

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INDEX

Hindalco Renukoot – Profile & Process introduction Background of the Project Concept of the Project Innovation in the Project Project Savings & Economics Challenges faced in implementation Measurement and Verification Potential for Horizontal Application Estimated Life of the Project

Hindalco Industries Limited, Renukoot

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Hindalco, the flagship company of the Aditya Birla Group and industry leader in aluminium and copper has consolidated turnover of US$17 billion & having footprint in 13 countries outside India. Finish Product Aluminium

Bauxite

Alumina Captive Power

800 MW

Hindalco-Renukoot: Fully integrated Operation

Hindalco Renukoot: Profile

Hindalco Industries Limited, Renukoot

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ALUMINA REFINERY

ALUMINA

BAUXITE

RED MUD STORAGE

ASH STORAGE

COAL

• CAUSTIC
• FURNACE OIL
• LIME
• SPECIALITY CHEMICALS

Power

WATER

Mud Cake Steam

Condensate

Slurry

Alumina Refinery: Renukoot

Hindalco Industries Limited, Renukoot

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“Caring for Energy…………….”

Background of the Project : Energy Consumption Trend

Hindalco Industries Limited, Renukoot

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LTD Unit-II 145 OC Flash Tank

HTD Unit-I 245 OC HTD Unit- III 245 OC

HTD Unit- IV 245 OC

Pressure decanter Bauxite Slurry

HRD

DCW

Mud To washer

Precipita- tion Calcina- tion

Alumina To smelter

Evaporation-III Evaporation-I Evaporation-IV Evaporation-II

Steam: ~60 TPH Steam Steam FO

Spent Liquor Strong Liquor Kelly Press Spent Liquor

Evaporation-II

“Evaporation is essential step in increasing process liquor concentration & maintaining refinery water balance.”

Make Up Caustic

Total Steam Consumption: ~250 TPH

Background of the Project

Hindalco Industries Limited, Renukoot

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Renukoot refinery operates on 4 evaporation units. Evaporation unit-II is the oldest unit among all four with steam economy ~2.92 T/T while Evap-I & newly installed GEA Messo Evap-IV runs on ~3.8 T/T. Steam economy of Evap-II unit has been the perennial problem and could not be solved by several initiatives taken in the past. Liquor flashing unit was installed in May-12 to reduce evaporation load of existing evaporation units. As a consequence one out of two bay of Evaporation unit-II stopped.

Performance of evaporation unit is measured by “Steam Economy”. (Evaporation Rate/Steam)

Background of the Project

Hindalco Industries Limited, Renukoot

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Evaporation Unit-II operating with two bays i.e “HID” and “Evaporator” Post liquor flashing Unit installation, “Evaporator” side bay stopped & “HID” side bay kept in operation. Performance with this setups.

Background of the Project

Hindalco Industries Limited, Renukoot

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• Several Brainstorming session held with cross functional teams, subject

experts and vendors to improve the Evaporation-II steam economy.

• There recommendation was to replace existing unit with latest

technology energy efficient units ( Expensive option).

• Fact finding mission was done to explore any stretch in key variables

and team arrived at “Is it possible to add additional effects for improving heat recovery thus increase in steam economy?”.

• To

evaluate the viability

• f

the idea and establishing key engineering/process specification, process simulation model developed

• n SYSCAD software & series of simulations carried out.
• Various Simulations were carried out to find out no. of optimum effects

along with the HID circuit and it emerged that adding 3 nos. effects is techno-feasible solution.

Concept of the Project

Hindalco Industries Limited, Renukoot

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Total duration 4 Weeks (complete flow- sheeting & programming).

• No. of Simulation Run i.e. 20 ( with

different setups/combinations (including Base case).

07/28/13 18:35:36 Project : Production_Upgradation 09Change09FC12 Evap (E:\Ameet SysCAD Work\SysCAD Projects\Final\Production_Upgradation 09Change09FC12 Evap.spf\)

UMO

Base Case 01 (with 2 Evap Effect) Case 02 (with 3 Evap Effect)

Case 03 (with 4 Evap Effect) HID body in line 3 3 3 3 Evaporation Body In line 2 3 4 Total Effect In Line 3 5 6 7 Liquor flow to New FF Tak m3/hr 600 600 600 600 Liquor Feed Flow to Evaporation m3/hr 320 320 320 320 Liquor Feed Temperature

OC

65.98 65.98 65.98 65.98 Liquor Feed Caustic Conc. gpl 246 246 246 246 Liquor Exit Temp From effect Heater to LSH

OC

107.3 111.5 112.9 114.0 LSH Htr Exit Temperature

OC

130 130 130 130 Liquor Exit Temp From last effect Flash chamber (Evaporation Discharge)

OC

91.16 86.57 85.04 83.83 Liquor Caustic Conc. From last effect Flash chamber (Evaporation Discharge) gpl 266.0 268.3 269.1 269.7 Vacuum on Barometric Condenser mmHg 600 600 600 600 Total vapor load on BC TPH 18.1 17.8 17.6 17.6 Water Required for BC @35 degC m3/hr 482 473 470 471 Water out from BC m3/hr 508 498 488 493 Water out Temp from BC deg C 56 56 56 56 Total Condansate out m3/hr 38.6 38.7 38.7 38.8 Condansate Temp

OC

61.5 61.5 61.5 61.5 Total Evaporation Rate (Evap+FFTk) TPH 33.2 35.9 36.7 37.4 Toatl steam Consumption TPH 15.7 12.8 11.8 11.0

Steam Economy T/T 2.12 2.81 3.11 3.39

Evaporation-II Phase-II (SYSCAD simulation Results)

Case no. 2 (i.e. 3 nos. Evaporator effects in line with the HID circuit) was selected for modification and implementation in the area

Concept of the Project

Hindalco Industries Limited, Renukoot

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Engineering done to feed input stream from evaporator side instead of earlier arrangement of HID

• side. This resulted into:
• Lower pressure drop because of its configuration (~1.1 Kg/cm2)
• Improved heat recovery as bigger Heat transfer area effects (i.e. HID effects) at highest

temperature end.

Innovation in Project

Evaporation Unit # 2 New Scheme ( HID side with Add. Effects in Operation – Phase II

Hindalco Industries Limited, Renukoot

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Another major challenge was vacuum system for evaporator effects with this configuration:

• Evaporator side vacuum system can not be taken in line due to conflicting configuration.
• Possibility was worked out to utilized HID side vacuum circuit, technical feasibility

worked out and found suitable & implemented.

Innovation in Project

Evaporation Unit # 2 New Scheme ( HID side with Add. Effects in Operation – Phase II

Hindalco Industries Limited, Renukoot

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Another area requiring engineering modifications was flexibility to revert in old configuration as during rainy season evaporation load may increase. Facility implemented with suitable provisions.

Innovation in Project

Evaporation Unit # 2 New Scheme ( HID side with Add. Effects in Operation – Phase II

Hindalco Industries Limited, Renukoot

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Saving Achieved

Hindalco Industries Limited, Renukoot

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Saving realization after Project completion

S # Parameters UMO Before After Total Diff (After- Before) Dec-12 to Apr-14 May-14 to May- 15

1

Steam Economy

t/t 2.95 3.42

0.47

2

Steam Consumption

TPH 13.4 10.9

• 2.46

3 LSH Temperature

OC

130 130 0.06

4 Evaporation Flow

m3/hr 315 325 9.65

Power Saving:

Saving Achieved

Hindalco Industries Limited, Renukoot

Pumps Pump Nos./HP Pumps Running (Nos.) Pumps Motor, HP Before After Before After

VT pumps 2 * 60 HP 3 NIL 310 2 * 125 HP Circulation Pump 270 + 250 HP 1 1 270 270 Discharge pump 1 * 40 HP 1 1 40 40 FF Tk. (N) Feed pump 2 * 75 HP 1 1 75 75 HID Feed Pump 2 * 215 HP 1 1 215 215 PLD Pump 2 * 40 HP 1 1 40 40 HID cond. Pump 2 * 10 HP 1 1 10 10 Evap cond. Pump 2 * 20 HP 1 1 20 20 IWR pumps 3 * 180 HP 3 2 540 360 Total 13 9 1520 1030

Power Savings (Before - After), HP (Motor loading assumed 85 %) 417 Power Savings (Before - After), KW 311

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• A. Investment:

S # Item

Size

Quantity Cost (Rs/Unit) Rs (lacs) Dia Length, mtr

1 Sh-40 Pipe 12" 50 3520 1.76 2 Sh-40 Pipe 10" 40 3433 1.37 3 T/F flange 12" 10 1236 0.12 4 T/F flange 10" 10 1236 0.12 5 Pipe Fabrication and Erection cost 12" 50 325.4 0.16 6 Pipe Fabrication and Erection cost 10" 40 271.8 0.11 7 Miscellaneous 0.10

Total Investment in Rs Lacs 3.75

Total Investment in $ ( 1 $ = 66.30 Rs as on 01-01-2016) $5,659

• B. Steam Saving Acquired

1

Steam Saving (Saving for 10

months from May-14 to May-15) 2.46 TPH 890 157.9

Total Saving in MTOE 1467 Total saving in $ ( @ 300 USD / MTOE) $4,40,100

• C. Power Saving Acquired

1

Power Saving (For 275 days per year) 310.71 KW 2.89 59.3 Total Saving in MTOE 176.36 Total saving in $ ( @ 300 USD / MTOE) 52908

Total Saving ( B + C ), $ USD/Annum $4,93,008

Pay Back Period (Days) 4.0

Project Economics

Hindalco Industries Limited, Renukoot

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Flexibility to revert on earlier configuration. Cost economics

Challenges Faced in Implementation

Space constraint Congested Layout of the unit

Hindalco Industries Limited, Renukoot

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Potential for Horizontal Application: Yes Estimated Life of the Project : Recurring

Key Parameters UMO Measurement Formula/Reference Verification Method

Steam Economy T/T Calculated = Evaporation Rate (TPH) / Steam Consumption (TPH) Evaporation Rate TPH Calculated = Feed Flow – [ Feed Flow * (Caustic in / Caustic Out)] Feed Flow M3/hr Flow Element Online Data from PHD Log Sheet: Doc No: DIG-LS-09-R2 FE Calibrated mid of the Month Caustic IN (Feed) gpl LAB instrument Sample Analysis in the LAB, Frequency: Every 4 hrs LAB: Potentiometric Titration Calibrated with Std. Solution. Caustic Out (Discharge) gpl LAB instrument Sample Analysis in the LAB, Frequency: Every 4 hrs LAB: Potentiometric Titration Calibrated with Std. Solution. Steam Consumption TPH Mass flow meter Online Data from PHD Log Sheet: Doc No: DIG-LS-09-R2 FE Calibrated mid of the Month

Measurement and Verification Arrangement

Hindalco Industries Limited, Renukoot

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Thank You