Aluminium Business 1 19 th National Award for Excellence in Energy Management – 2018 Asia’s 1 st ISO-50001 certified Smelter Team Members: Bibhudatta Mohanty – Associate General Manager Manoj Senapati – Associate Manager Dilip Kumar Satpathy – Associate Manager
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19th National Award for Excellence in Energy€¦ · Garmco(Middle East) Hindalco, etc Wire Rod Mill Technology • SOUTHWIRE, USA • Properzi, Italy. Plant Capacity • 120 KTPA
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Aluminium Business1
19th National Award for Excellence in Energy Management – 2018
8 Installation of energy efficient Air conditioner 0.11 0.37 3.47 113.00
9 Lighting Automation in different areas of plant 0.09 0.29 0.03 1.00
10CWP 4 Drive installation and to be run in 80%
capacity mode.0.09 0.29 0.31 13.00
11CT1 Drive installation and to be run in
temperature feedback control mode0.08 0.25 0.07 3.00
12Optimization of run time Grouping Hydraulic
motor by removal of lift shift operation0.07 0.22 0.00 0.00
13 Daytank heater set point optimisation . 0.06 0.20 0.00 0.00
14vacuum unit idle time reduce from 10 minutes
to 5 minutes.0.05 0.16 0.00 0.00
15 WCS cooling fan run time optimization 0.04 0.12 0.00 0.00
Total energy savings for FY 2017-18 = 34.22 Million Kwh
Aluminium Business14
MAJOR ENERGY SAVING PROJECTS
(FY 2017-18)
Sl.No Project descriptionEnergy saving in MkWh/Annum
1 SGL100% cathode implementation 25.34
2 SHANDONG cathode implementation 5.91
3 FTP air slide fan optimization 0.65
Spare a Watt; Save a Lot
Aluminium Business15
SGL100% CATHODE
Existing 50% graphitized cathodes are replaced with 100% graphitized cathodes.
Benefits of implementation:• Resistivity reduced from 26 ohm-cm to 12 ohm-cm.• Operating Voltage decrease from 4.182V to 4.126V• CVD (Cathode voltage drop) decreased to 247mV from 385mV• Which resulting a huge energy saving by the reduction of Specific DC energy consumption from
Improvement Actions Taken:➢ Optimization of pulsing oil injection in heating ramp. i.e, Firing of oil started after 8 hours of fire changeover maintaining CRR of
92%.➢ Peep hole modification done by putting ceramic coating cloth in it by reducing top surface temperature from 346 degree Celsius to
185 degree Celsius.➢ Gap between burner stand & ring is covered with packing coke.
Way forward:➢ Firing system level-2 SCADA up gradation for monitoring of flooding index of HFO and CO2.➢ Provision of flow meter in each ramp for better monitoring of HFO consumption.
Gap between burner stand & ring
Gap covered with packing coke
No covering around burner base
Covered with coke around burner base
Aluminium Business25
CARBON FOOT PRINT ACTIVITIES
Reduction in Specific Diesel consumption
2.7
2.72
2.74
2.76
2.78
2.8
2.82
2.84
2.86
FY'16-17 FY'17-18 FY'18-19(Target)
2.85
2.81
2.72
Improvement Actions Taken:➢ To optimize the idle running of engines in full RPM at the time of seal changing and pressure making in workshop, external compressor
unit installed to perform the pneumatic related operations in metal tapping vehicles.➢ Shortest path identification for process vehicles movement in plant premises.
Way forward:➢ Software up gradation in 2 MTVs by changing the controller and related programming so as to get the fuel savings like MTV 15
Aluminium Business26
CARBON FOOT PRINT ACTIVITIES
Reprocessing of Spent Pot Lining (SPL)
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
2015-16 2016-17 2017-18
684.24 1003.54
9005.5
Quantity of SPL(MT)
Way forward :
Tie-up with Green Energy Reprocessor for evacuating 4,200 MT per month with a vision of evacuating
entire SPL from our site in a time span of 18 months.
Aluminium Business27
E-DMS DOCUMENT CONTROL & APPROVAL
ENERGY EFFICIENT PROCUREMENT
DIGITISATION OF EnMS
E-CER (CAPEX PROJECT) ENERGY IMPACT ASSESSMENT
MES ONLINE FLASH REPORT
“Automation leads to Perfection”
Aluminium Business28
ENERGY MONITORING & REPORTS
SEC Report to Plant Head
Section Wise Report to Energy Managers
Daily reports to HODs
Energy Management SCADA
Parameters & Monitoring Frequency
High Energy Consumers Daily
Fuel Consumption Daily
Compressed Air Consumption Daily
Water Consumption Daily
“Monitor to Control”
Aluminium Business29
Non-Conformity Statement :
➢ In significant activity sheet maintenancerelated activities which impact to theenergy performance was notmentioned.
Corrective Actions Done :
➢ Significant activity sheet prepared forthose maintenance activity which isimpacting energy consumption.
IMPLEMENTATION OF CORRECTIVE /
PREVENTIVE ACTIONS
Aluminium Business30
Flow measurement
Major Energy Consumers
• Integrated Energy Meters are installed in the Sub Stations
• Related Process parameter are displayed on the screen
• Data is captured from these resources at regular intervals
Other Energy Consumers
• Energy consumption is measured by Power Analyzers before & after the Project for quantification of savings
• Flow measurements are taken for quantification of savings before & after the project
• Fuel consumptions are validated by third party auditors every month
• Meters used for all measurements are calibrated as per ISO Standards
“Well defined measurement system to quantify & validate ”
Energy measurement
Integrated Energy Meters
Flow measurement
ENERGY MONITORING & QUANTIFICATION
Aluminium Business31
ENERGY CONSERVATION WITH TQM
“Improvement is an Infection”
2016-17 NOS.
SAVING
INVESTMENT (Rs. In Million)
NOS. OF PEOPLE INVOVEDPOWER
(Million Units/Annum)COST
(Rs.in Million)
SIX SIGMA 1 0.65 2.15 0 12
QC 2 0.64 2.11 4.07 10
KAIZEN 17 2.85 5.62 7.955 to 6 members in each
project
Conserve to Preserve
Aluminium Business32
PEOPLE INVOLVEMENT
Energy Dash board on Shop floorEnergy discussion in daily War-room
Energy awareness in Tool Box Talk.Awards & Recognition for Energy
initiatives
“We value every small contribution”
Aluminium Business33
ENERGY CONSERVATION WEEK
Cherish the earth through energy conservation.
Aluminium Business34
Energy Policy
Energy Review
EnPI
&
Sub- EnPI
Opportunity List
Objective, Targets &
Action Plan
Monitoring, Measurement
Analysis & Review
Energy Audit , Corrective &
Preventive action
ENERGY MANAGEMENT SYSTEM
(ISO-50001)
1st Smelter in Asia ISO-50001 certified
Aluminium Business35
REVIEW STRUCTURE
Formation of Energy Cell
SBU level energy review
Review by Energy Manager
Management review by Plant
Head
Monthly operation review
by Head Aluminium operations
Corporate Sustainability
review
APEX Committee
CORE Committee
COORDINATING
CommitteeSGA Team
“Bottom to Top Approach”
Aluminium Business36
ENERGY POLICY & OBJECTIVES(2018-2019)
ENMS OBJECTIVES
▪ Reduce DC Energy Consumption▪ Reduce Auxiliary Energy Consumption ▪ Reduce HFO Consumption ▪ Reduce Diesel Consumption
Aluminium Business37
Air Pollution Management
• De-dusting units along with bag filters
• Introduction of Electro Static Precipitator (ESP)
• Installation of CAAQMS for continuous air quality monitoring
Water Pollution
Management
• Online waste water monitoring system
• Storm water guard pond
UF & RO PlantReal time monitoring of ambient air
ENVIRONMENTAL PROJECTS & INITIATIVES
Every action has a reaction
Aluminium Business38
Waste Management
• Segregation biodegradable & non biodegradablewaste
• High Concentration Slurry Disposal (HCSD) -1st In Odisha
Water Conservation▪ Treatment and recycling of effluent water▪Principle of “Zero” effluent water discharge▪Upgrading ETP with Ultra-filtration & Reverse Osmosis for maximum water recycling.▪Storm water guard pond for management of storm water.▪Installation of robust quality of float vales to avoid overflow of water from sintex tank.▪Recycling of Ash pond water for using in ash handling plant
Rain Water Harvesting• A study on Rain Water Harvesting has been
conducted by Andhra University and the report has been submitted to CGWA / OSPCB for their technical suggestion.
• Approval received from CGWA.
ENVIRONMENTAL PROJECTS & INITIATIVES
“Every drop counts”
Aluminium Business40
“Each one Plant one” taken on world Environment Day in which all employees & contractors have planted one tree across the location
Environment Incident Management System
Waste Management Systems under Sustainability Framework
Rehabilitation of Ash filled area by plantation
Green Jharsuguda Project – in PPP mode 100750 saplings at Behrapat, Lohrabudh & Banjari village
INITIATIVES FOR A GREENER TOMORROW
“Fulfilling our dream of Clean & Green India”
Aluminium Business41
ENCON EFFORTS –A NOTCH UP
Energy Audit by CII
Energy Audit by TERI
EnMS Implemented
ISO 50001 Certified ENCON award from BEE and CII
ENCON award from BEE , CII & GMEA
Russian Gov. Award-Best Energy Efficient project realized abroad
FICCI audit, M&V audit-PAT
NECA -2nd Prize
Energy Management Insight award
PAT cycle-1 best achiever award SEEM award
2010
2011
2014
2012
2015
2013
2016
2017
Clamp Drop
Fuse Technology
Slotted Anode
Cathode &
HFO
HFO & Conversion Efficiency
Technology up gradation in potline
Aluminium Business42
ENCON PROJECTS
(Ongoing/Upcoming)
“Our plans for a better Tomorrow”
Sl.no Title of Project YearEstimated Annual
Savings, MkWh
1 Revamping of homogenising furnace and up gradation of insulation 2018-19 3.577
2Pot controller and lining design up gradation to improve specific DC
energy consumption2018-19 324
3 VFD installation for pumps and fans 2018-19 15.4
4 Energy efficient coating on pumps 2018-19 0.29
5Interconnection hot water line with make up water line to switch off
filter feed pump in casthouse2018-19 0.482
6Current efficiency improvement in pots to reduce specific DC energy
consumption2018-19 101
7 Use of graphite particle instead of resistor coke 2018-19 1.65
Aluminium Business43
Adoption of New technology of Cell lining
Up-gradation of Pot Control & Feeding System
ROAD MAP TOWARDS BENCHMARK
MV drive for FTP ID Fan
HFO SCADA level-2 upgradation
“Measure to Control, Benchmark to Better”
Aluminium Business44
AWARDS & RECOGNITIONS
Recognition is the greatest motivator
✓ Recognized as “Energy Efficient Unit” at 18th
National Award for “Excellence in Energy Management” organized by CII.
✓ Silver award for best energy management from SEEM.