Aluminium
Unit Profile
HINDALCO industries limited (Hindustan Aluminium Company limited) is the largest manufactures of primary aluminium in India and also one of the largest manufactures in the world. HINDALCO is vertically integrated through every stage of the industry including bauxite mining, alumina refining, alumina smelting, semi-fabricating (sheets and foils), product development and captive power generation. HINDALCO Hirakud Smelter is located at Hirakud in Orissa. Hirakud smelter plant pursues production of primary metal, which is based on electrolytic reduction. Expansion and modernization project for increasing the smelting capacity to 146 KTPA presently is completed recently. In the last year Hirakud smelter has successfully converted the HSS (Horizontal Stud Soderberg) Pots to pre-baked pots. The conversion has resulted in high energy saving reducing the DC energy required for smelting process. For meeting the extra power requirement the captive power plant at Hirakud is also expanded from 67.5 MW to 367.5 MW. HINDALCO Hirakud smelter has also taken a coal mine known as Talabira mines near Jharsuguda district of Orissa for meeting the coal demand of its power plant.
15
Energy Consumption
With the implementation of various energy conservation projects and the conversion of HSS pot lines to Pre-Baked pots has resulted in substantial energy reduction. There is steady decline of specific energy consumption in the last three years. Below table and graphs shows
UNIT
Lakhs Kwh
Specific energy consumption Kwh/tonne (electrical) Total thermal consumption energy Mkcal
25 20 15 Ltr/ton 10 5 0
kwh/ton
Seri
year
16
17
SGA Team
Energy Policy
Energy efficient power generation, aluminium smelting and casting Nurturing energy efficient designs and technology for all future acquisitions, where ever practicable Enhancing utilization of renewable energy resources, wherever feasible Recognizing efforts of our employees and their family members in energy conservation initiatives Going beyond standards, wherever economically viable Yardsticks, which drive us to monitor and improve energy performance through periodic reviews and skill up-gradation of our employees.
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1. Reduction of DC energy in newly started 85 KA prebake pots by implementation of anode effect termination (AET) technology Before Installation: Before installation of this project the anode effect was killed manually and it was very time taking and also the anode effect duration was high. Before
Energy consumption When HSS Power consumption was 14260Kwh/ton. During prebaked consumption is 14000Kwh/ton. Saving in FY-2007-08 is 425845560kwh.and Rs.258lakh
After installation: In this project they have modified both hard ware and soft ware of the electronic pot controller. After the modification the anode effect killing time has reduced due to auto killing by the controller.
After
2. INSTALLATION OF VVFD FOR COLDWELL MOTOR OF COMPRESSOR COOLING TOWER Situation Before Earlier there was a star delta starter running the motor at full speed and as the pump is of higher size than requirement so the flow and pump of the water line was adjusted with reducing valve opening. Due to reduced valve opening the pump was operating at lower efficiency and friction head losses were more. Situation After After installation of VVFD the valve was made fully open and the pressure and flow is adjusted by varying the motor speed through VVFD. Due to low speed operation the motor is operating with half of the power required before. Total investment-Rs.1.5lakh Saving-Rs.3.45lakh/year
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3. REPLACEMENT OF OLD AIR COMPRESSOR LINES Situation Before The compressor airline was forty years older and there were many leakages in the line, due to this leakage they had to run one more extra compressor for meeting the load demand than the requirement. Also the airlines were laid under the tunnel, so it was very difficult to maintain them. Situation After After changing of the old compressor line with new one laid over head, running of one number of compressor was no more needed, so by this they reduced one number of compressor to run. Total investment-Rs.15lakh Saving- Rs.6.4 lakh (recurring)
4. Demand based switching of air compressors Before installation There are 10 numbers of air compressors for supplying compressed air to the pot line, most of them were running in unload condition for most of the time due to unavailability of sufficient control mechanism, with this they were loosing a lot of no load power consumed by compressors After installation After using this PLC controlled circuit they had saved a lot of power by switching the compressors on the basis of load demand and with complete closed loop control. Installation cost-Rs.60,000 Saving-Rs.90,000/year
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S.NO 1 2 3 4 5 6
ACTION PLAN Conversion of existing 172pots to pre baked technology Installation of auxiliary energy management system for monitoring of auxiliary energy Installation of VVFD for IR compressor cooling tower Installation of capacitor bank for plant auxiliary sub station Replacement of old rectiformers of rectifier station Installation of VVFD for compressor cooling tower
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Second Prize
Aluminium
Unit Profile
Hindalco Industries Ltd. (Hindalco), a Flagship Company of the Aditya Birla Group is a Pioneer nonferrous metals powerhouse. Hindalco was incorporated in 1958. Its Renukoot unit was set up in technical collaboration with Kaiser Aluminium and Chemicals corporation, USA and commenced commercial production in 1962.
Hindalco, at Renukoot, houses a fully integrated plant, comprising of 3 main plants i.e. Alumina, Smelter & Fabrication Plants. Hindalco produces some Byproducts, which include Gallium Metal, Vanadium Sludge and Aluminium Dross. Each plant employs varying Technology. With integrated facilities, output from various plants is used by next, along with varying raw materials. Company has its own captive power plant at Renusagar (30 Km away from Renukoot) with installed capacity of 741.7 MW and 78 MW of CoGeneration Plant at Renukoot itself. Alumina Plant: - It was commissioned with an initial capacity of 40,000 MTPA, which has now increased, to 700000 MTPA. The plant has been expanded in phases using new technology from time to time for energy efficiency and capacity enhancement. It employs the basic Bayers process and the major raw materials for the plant are Bauxite, Steam, Caustic Soda and Furnace oil. Aluminium Smelter: - It has 11 Pot lines with 2127 Pots installed with annual production capacity of 3,45,000 MT. The Smelter employs the Hall Heroult Electrolysis Process for the extraction of Aluminium from Alumina. Basic raw materials for the smelter are Alumina, Power, Anodes and Aluminium Fluoride. Fabrication Plant (Value Added Products): - The Fabrication Plant at Renukoot comprises of 4 Main Sections Remelt Shop, Cast House, Rolling Mills, Extrusion & Conform which produce Wire Rod, Slabs/Billets, Rolled, Coils and Extruded Products. Hindalco, an ISO 14001, ISO 9001:2000 and OHSAS 18001 Company. Recently these three systems have integrated as IMS (Integrated Management System). Today Hindalco occupies a place of pride in the global aluminium scenario with its most efficient working in all areas of operations. The company has kept pace all along with latest development in aluminium technology and has upgraded its manufacturing facilities. 22
Energy Consumption
Manufacturing of Aluminium is one of the most energy intensive process. The cost of Energy comprises about 41.40 % of the total input costs for producing Aluminium. Hindalco uses 3 types of Energy resources to manufacture Aluminium i.e. Coal, Oil and Electricity. Out of these three, electricity has the highest share (almost 75.23 % of total energy consumption cost). Total cost of energy for last year was Rs. 893.23 Crore, which includes Rs.161.02 Crore for Fuel oil, Rs.672.01 for Electricity, and Rs.60.19 Crore for Coal & purchased steam. Last year company consumed 491836 MT of Coal, 83263.20 KL of Fuel Oil, 61127.15 Lakhs kWh of Electricity and 264329 MT of purchased steam.
ALUMINIUM
3.413
0.503 0.487
2005-06
2006-07 YEAR
2007-08
2005-06
2006-07 YEAR
2007-08
Billet Casting
0.350 0.300 0.250 0.200 0.150 0.100 0.050 0.000 2005-06 2006-07 YEAR 2007-08 0.320 0.330 0.329
0.320
0.290 0.255
2005-06
2006-07 YEAR
2007-08
kWh / MT
kWh / MT
23
63.000
kWh / MT
62 59 57
328
328
2005-06
2006-07 Year
2007-08
Since the company has strong commitment towards Energy Conservation, the projects, which require investments, are normally approved. Company takes special care to allocate funds for these projects. A Top Down and Bottom Up approach through out the organization is maintained towards Energy Conservation.
25
Year
26
Reduction in surface heat loss from Billet & Cast House Furnaces by changing design of refractory insulation.
Revamping of 3 Nos. Soaking Pit for improved insulation leading to reduced losses. Investment 102.90 Lac Money saving = Rs.26.81 Lac/Year
Reduction in Sp. Fuel Consumption of Wire Rod by improving combustion efficiency & changing the SOP.
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To circulate the CEP water through the Gland Steam Condenser to increase the feed water temp thus saving in coal consumption. Investment 2.50 Lac Money saving = Rs.55.01 Lac/Year
31.4MWTG Condensate
B#3 Deaerator
ejector
Interconnection of ACW and CW pump was done and two nos. ACW pumps were stopped during winter season to reduce the auxiliary power consumption. Investment 0.75 Lac Money saving = Rs.19.44 Lac/Year
Turbine d
ACW pp
CW pp
In addition of above, following 38 major projects have been implemented during FY 07 08. Saving (Rs. Lakhs) 3.56 3.98 0.92 0.15 1.72 7.37 2.05 2.32 Investment (Rs.Lakhs) 3.00 3.00 0.20 0.15 0.01 1.29 0.65 0.10
SN 1 2 3 4 5 6 7 8
PROJECT DESCRIPTION Evaporation -3 Feed Pumps : Replacement of 150 HP motors by 200 HP motors to avoid duplicate equipment running . Evaporation -3 Homo Liquor Pumps : Replacement of 150 HP motors by 200 HP motors to avoid duplicate equipment running . Installation of float switch to avoid idle running of New ETP Pit sump Pump Installation of energy efficient light in Evapn - 3, Coal tippler & PPT area Control logic has been introduced on DCS to optimize the running of additional condensate pump in precipitation area. Washer over flow pumps speed optimization as per washer over flow tanks level to reduce power consumption. Lime slurry feed pump speed optimization as per additive lime tank level to reduce power Stopping the medium pressure purge water pump used for cooling the gland of Digestion # 1 Blow off pump and bearings of Charge pump & Booster pump of Digestion # 1 & 2 by providing spool.
28
10
11 12 13 14 15 16 17 18 19 20
To stop one small cooling tower by providing the circulating water to all the three bundles of flux cooler of FCB Calciner by increasing the pipe dia from 4" to 6". Development of sweetening control scheme to run sweetening in both Digestion unit # 1 & 2 through single pump instead of dedicated pump. Development of Ball Bill idle run hour software for Ball Bill of Alumina Plant in DCS for close monitoring. This has reduced the specific energy consumption by 3 Units/MT. Primary Feed System Blower stopped through air taken from air lift blower in FTP line-5, 6 & 7. Primary air-slide fan of FTP line-8 stopped by capacity utilization of air lift blower. Filter hopper fluidization fan of FTP of Pot line # 5 & 6 stopped by supplying the air from pot air slide fan. Energy saving by reducing pulley ratio of air lift blowers in Pot line8 FTP. Installation of transparent sheet in roof of Billet casting Area to reduce the ON time of roof lights. Automation of cooling tower fan to control water temperature in the range of 28 to 33 Deg C. Reduction in soaking time of few alloys at Billet Casting Homo furnace to reduce the power consumption. Stopped the running of Sniff Nozzle during non casting time. Making of Sow cake for sell from left out metal of furnace for selected alloys (1050, 1060 &1070) after casting to reduce the scrap generation. Provided the push button and indication lamp for air filter fan on the operator panel of compressor to avoid the idle running. Relocation of switch boards of Stack lights of Pot line # 6 to 11 to avoid the idle ON time. Installation of automatic light sensor in Bath crushing area lights to avoid the manual intervention thus reducing the ON time. Stoppage of Idle running of RAL motor of Pot line # 4 DSS second phase. Replacement of HTM heater with inline oil heater in Slab Casting Furnace. Revamping of Homo Furnace to decrease the heat loss. Interlocking of circulating fan of Solution furnace to avoid the idle running. Replacement of Motor of Caster scrubber unit pumps from 10 HP to 3 HP. Interlocking of LNP coolant pump motor of Davy Cold Mill to avoid the idle running of motor. Feed water heater provided in Co-Generation - 1 to increase the feed water temperature thus saving in coal. Modification in pipe fittings of ash handling line of Boiler # 3 to reduce false air ingress thus reduction in running hour of vacuum pump. Modification in water pipe line of VAM to match the requirement.
5.03
0.20
5.80
0.50
38.28 1.46 1.22 0.31 0.54 0.38 1.31 1.80 0.70 3.36 0.09 0.11 0.03 1.18 1.45 0.48 0.10 0.80 0.09 53.80 2.24 7.05
0.00 0.05 0.20 0.02 0.06 0.56 0.05 0.00 0.00 0 0.02 0.02 0.01 0.25 0.30 40.00 0.00 0.00 0.00 15.60 4.60 0.50
21 22 23 24 25 26 27 28 29 30 31
32
29
33 34 35 36 37
38
To stop the sample cooler pump by providing the connection from raw water line. Provision of on line removal of deposits from 5.6 MW turbine by the use 100 PSI steam to increase the power generation. Relocation of switches for lights of Boiler # 4 by-room to reduce the ON time. Installation of timer in lighting circuit of Co-Generation # 2 condenser area lights to reduce ON time. 3 Nos. air compressors each of 11.2 KW discarded after replacement of Air Blast Circuit Breakers with SF6 Circuit Breakers at Rectifier-II. Development of pump runs hour software for all power intensive pumps of Alumina Plant in DCS for close monitoring. This has reduced the specific energy consumption by 7 Units/MT.
89.32
0.00
Besides above, a number of energy conservation projects have been completed through Small Group Activities; only some of these have been included above.
Energy Conservation Measures To convert existing high temperature Digestion technology with energy efficient double digestion technology. Construction of drain channels to connect all individual sump pits in filtration area to avoid the individual running of sump pumps to save power. De-linking of Evapn. unit II and III for increasing evaporation rate on account of reduced BPR and stopping one pumping station and power saving. To arrest escapage of HRD waste vapors to heat wash water. To enhance throughput of Ball Mill # 4 from 38 to 48 TPH to reduce the specific power consumption. Efficient way of doing condensate cleaning of precipitation tank air lifts by process generated hot condensate in place of clear water to save steam energy for heating the same. BM # 1 GMD Pump (N) -Motor Rationalization (25 HP-15 HP) BM # 4 GMD Pump (N) -Motor Rationalization (60 HP-40 HP) Piping modification for rerouting Digestion # 3 & 4 dilution lines through Washer # 1 over flow pumps thus removing existing pumping station for unit 3 & 4. 30
2.18
0.75
2008-09
95.89
2.50
2008-09
4 5
3.86 12.00
41.20
2008-09 2008-09
1.04
0.127
2008-09
7 8
0.41 0.69
0.76 1.05
2008-09 2008-09
4.24
0.50
2008-09
Piping modification for catering requirement of 10 sweetening slurry for Digestion unit # 1 & 2 with one pump in place of two separate pumps. Installation of capacitor bank in New Drum Filter 11 MCC, Evp3 MCC, Old PPT MCC, Bauxite Tippler MCC & Ammonia Compressor MCC. Installation of energy efficient light fitting in PPT 12 & Clarification area. Spent Liquor Tank Agitator : Motor H.P 13 rationalization (25 HP motor by 10 HP motor) Installation of VFD in Main Air Slide motors of 14 Plant-2 Reduce energy consumption by increasing 15 anode life from 76 shift to 80 shift. Reduce energy consumption by using bigger 16 size cathode blocks in electrolytic pot. Trial to be taken in 90 Pots in FY 08 - 09 To reduce oil consumption by improving flue 17 design. Reduce steam consumption by using 100% 18 molten pitch in paste plant To stop the Rotary air lock of line-4 DSS 19 hoppers (Phase - 1) by providing a bypass line for discharge of alumina in air slide Energy saving by optimizing the time of fluidization of air slides of Automatic alumina 20 Feeding System of pot rooms by change in the PLC programme. Optimize the running rpm of ventilation fans of 21 Alumina Transfer System between plant # 1 & plant # 2 through V.F.D. Stopping of main air slide fan in FTP of Pot line 20 - 9, 10 & 11 by utilization of additional capacity of filter hopper blower Revamping of Homo furnace electrical control 21 system. Automation to avoid the idle running of cooling 22 fan of Blue star STL DC motor. Modification in hydraulic pipe line Extrusion 23 Press # 5 Platen saw so that one hydraulic power pack could be eliminated. Revamping of one no D C Melting & Holding 24 Furnace of Remelt shop to reduce Radiation Loss. To install Variable Frequency Drive in the FD 25 Fan motor of Co-Generation unit # 1. To install Variable Frequency Drive in the FD 26 Fan motor of Co- Generation unit # 2. To replace Boiler # 2 de-aerator feed pump by 27 Energy efficient feed pump.
3.79
0.10
2008-09
7.26
3.06
0.5
2008 - 09
13.79
0.7
2008 - 09
1.13
0.5
2008 - 09
8.18
44.0
2008-09
31
To install RO plant for polishing process 28 condensate coming from Alumina plant for saving of water. Bypassing of A/C cooling tower by providing the 29 water from transformer cooling tower in Pot line # 9, 10 & 11 Switch house Air conditioning units.
16.12
133.00
2008-09
0.80
0.20
2008-09
32