Innovation Energy Management - CIIGBCgreenbusinesscentre.com... · Vedanta Limited, with 51% stake...
Transcript of Innovation Energy Management - CIIGBCgreenbusinesscentre.com... · Vedanta Limited, with 51% stake...
Vision : To be a World Class Integrated Aluminium & Power Producer Generating Sustainable Value for All Stakeholders
Care
Respect
Innovation
ExcellenceIntegrity
Trust
Entrepreneurship
CORE VALUES
CII
Award for Excellence
in
Energy Management
Vedanta Limited, Aluminium - BALCO | 1
Balco Overview
Bharat Aluminium Company (BALCO) has made significant contributions as
the,1st PSU in India’s Aluminium sector Incorporated in 1965, BALCO is
India’s first integrated Aluminium business.
One of the first disinvestments of the Government of India. It now a part of
Vedanta Limited, with 51% stake held by Vedanta Limited and 49% held by
Government.
Balco is based in Chhattisgarh State having Captive Bauxite mines in
Mainpat and Kawardha, Captive coal mines in Chotia, 2010 MW power
generation capacity and 5.7 LTPA Aluminium Smelting capacity at Korba
Complex.
Balco produces Wire rods, ingots, Alloy rods, Alloy ingots and Rolled
products. Balco is also selling power.
Balco has been India’s first - to have Captive Power Plant, to venture into +
300kA Prebake pots, to produce Alloy Rods for conductors used in power
transmission industry, to roll material for Aerospace in the Country, online
riser replacement and busbar insulation in potroom and single beam
implementation, holds patent for aluminium cell fuse technology.
Vedanta Limited, Aluminium - BALCO | 2
Process Flow –Aluminium Production
Prebaked Rodded Anode
Butts
Crust
Bath
Fumes after
Dry scrubbing
FumeEnriched
Al2O3
Cast house
DC Power
Cryolite, Soda, ALF3
Bamboo
UtilitiesAir
Carbon
Liquid Al
To the air
Central Store
FTP
Electrolyte cell
(Pot)
Captive Power Plant
Stack
- Electrical Power as
part of COP – 38%
- Electrical Power as
part of energy
consumption – 98%Prebaked smelting processes (Hall Heroult) involve electrolytic reduction
of the Alumina by Carbon to Hot metal and Carbon dioxide.
2 Al2O3 (dissolved) + 3C(s) ------> 4Al(l) +3CO2(g)
Technology Provider –
Potline1 GAMI (320KA),
Potline2 GAMI (340KA)
Vedanta Limited, Aluminium - BALCO | 3
Certifications, Energy Policy and Objectives
1. Reduce Net AC Power consumption to 12720 KWH/Mt-Al
2. Reduce Auxiliary Power Consumption to 380 KWH/MT-Al
ENERGY OBJECTIVES (Vision FY21) :ENERGY OBJECTIVES (FY18) :
1. Reduce Net AC Power consumption from 14139to 13680 KWH/Mt-Al
2. Reduce Auxiliary Power Consumption from 438to 417 KWH/MT-Al
S. No Description Certification
1 Quality management system ISO 9001:2008
2 Environment Management System ISO 14001:2004
3 Occupational Health & Safety
Management System
OHSAS 18001:2007
4 Energy Management System ISO 50001:2011
5 Asset Management System ISO 55001:2014
6 International Automotive Task force TS 16949
Vedanta Limited, Aluminium - BALCO | 4
Energy Conservation Journey & Review Mechanism
Corporate Sustainability Review
Monthly Management Review by CEO
Monthly Operational Review by Plant Head
Weekly Energy Cell review by Energy
Manager
SBU Level review – Daily War Room
Energy Excellence Model
Bench-
marking
Innovatio
nAwareness
Involveme
nt
Certific
ation &
Awards
Energy Saving, Cost
Reduction, Sustainable
Operation
Vedanta Limited, Aluminium - BALCO | 5
Global benchmarking & Energy Conservation Vision 2021
54.451.1 50.8 49.3 49.2 48.6 49.1 48.5 47.5 45.8
FY 14 FY 15 FY 16 FY 17 Indian BenchmarkInternational Benchmark FY 18 FY 19 FY 20 FY 21
Energy Consumption (GJ/MT)
S. No. Major Projects / Action Plan for Vision FY 21 Power Saving UnitTarget
Completion
1 Reduction in Pot-line Aux. power consumption to 380 KWh/MT 53 Kwh/MT Dec-17
2 Installation of 100% graphitized Cathodes 48 Kwh/MT on monthly basis Mar-20
3 Up gradation of Pot-control system in Pot-line 1 250 Kwh/MT Feb-18
4 Up gradation of Pot-control system in Pot-line 2 250 Kwh/MT May-18
5 Increase in Pot-line Current Efficiency from 93.38 to 94.48% 140 Kwh/MT Mar-18
6 Installation of air cooled cathode tabs in collector bar 400 Kwh/MT Sept-19
7 Installation of Energy efficient RUC cathodes 700 Kwh/MT Mar-21
Vedanta Limited, Aluminium - BALCO | 6
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Potline DC Sp/ Power Benchmarking
Vedanta Limited, Aluminium - BALCO | 7
Major Energy Conservation Projects
S.No Title of Project
Annual Energy
Saving Million
KWH
Investment
Million
INR
1 Energy reduction in Utility area (Compressor and pump houses) 3.6 -
2 Use of 100% Graphitized Cathode (done in 98 pots) 44.71 84.6
3
Cast House 2- 1. LTA to be reduce to 15 min so has to utilize metal heat from
Pot-room,2.Improving Air to oil Fuel ratio in HF 1 and HF 2 for less oil
consumption. 0.3 -
4Rodding 2- 1. Minimize idle running hours in all bet conveyors,2.-Installation
of timers in all De-dusting unit,3.Induction Furnace Process Optimization. 0.09 -
5Installation of 10000 18 W LED tube lights in place of 40 W conventionaltube lights through EESL scheme 0.91 1.9
6Installation of Motion Sensors for lighting control in Washrooms / Conference
room
0.09 0.3
7 Installation of no's 420 90W LED Street lights in place of 250W HPSV 0.3 3
8 Installation of LED Down-lighter lights in Canteens 0.04 0.34
Vedanta Limited, Aluminium - BALCO | 8
S.No Title of Project
Annual Energy
Saving Million
KWH
Investment
Million
INR
9 Close loop provision in Compressor & Rectifier pump house -1 & 2 0.3 4.5
10 One compressor Air end up-gradation 1.72 2
11 Conversion of Lighting load to Solar 1.63 9.6
12 Installation of VFD for Cold well pumps in ACH 0.3 2.5
13 NCRM AC Plant cooling water system to be merged with RCW line. 0.3 0.5
14 Use of Induction Cooktop in place of Nichrome based heaters in Canteens. 0.15 0.5
TOTAL 55.47 110.64
Major Energy Conservation Projects Contd.
FY Project DescriptionInvestment
(Rs. Crs)Turnover (Rs. Crs)
% Investment on Turnover
2016-17 100% Graphitized Cathodes 84.6 6400 1.3%
2017-18 Pot Controller upgradation and 100% Graphitized Cathodes 154.1 9063 1.7%
2018-19 Cathode Air cooled taps and 100% Graphitized Cathodes 126.2 9063 1.4%
%Investment for Major Energy conservation projects on Turnover
Vedanta Limited, Aluminium - BALCO | 9
Project Start Date : 01-04-2016
Project End Date : 31-03-2017
Problem Statement:- The specific power consumption
was more than 13,300 KWH/MT of hot metal for semi
graphitized cathodes.
Data Collection :- To collect the historical data, pots
were chosen having same cell design, located within
same pot line and similar age. Cathode voltage drop
(CVD) and wear rate of cathode were taken as
performance indicator.
Project 1-100 % Graphitized Cathode with variable slot depth design
Specific Power Consumption of Semi graphitized
cathodes:-
S No. Cathode Block Power Cons.
(DC)UOM
1 Semi graphitic A 13286
KWH/MT of
Hot Metal2 Semi graphitic B 13349
3 Semi graphitic C 13412
Vedanta Limited, Aluminium - BALCO | 10
C
3D graphical representat ion of the VSD
Collector bar
Slot VSD
Cathode-bottom block
1. ACD (anode to cathode distance) reduction was also given priority as energy reduction was the objective but it
comes with the adverse effects of decreasing the pot temperature and instability. Variable slot depth design
(VSD)was developed to manage this problem, SD gives more homogeneous current density distribution and there
by increased stability which allows ACD reduction.
2. The higher thermal conductivity of graphitized cathode compared to semi graphitized cathodes, required added
insulation within the cell lining to maintain the same thermal balance without increasing the energy required to
operate the pot.
New lining design keeps the heat in the pot, i.e. reduces thermal losses.
Uniqueness of the project
Vedanta Limited, Aluminium - BALCO | 11
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CV
D (
in m
v.)
Age (in Days)
CVD Trend of different cathodes
Data Analysis, Countermeasures & validation
Wear rate comparison:-
S No. Cathode Block Max wear
rate(mm)
Predicted life
(Days)
1Graphitized
cathode with VSD68,8 2613
2 Semi graphitic A 139,8 1356
3 Semi graphitic B 145,8 1073
Vedanta Limited, Aluminium - BALCO | 12
Results:- Cathode Voltage Drop and wear rate has been substantially lowered than reference semi graphitized
cells and leading to reduction in Specific Energy Consumption and satisfying project target.
Comparison of measured CVD
between Reference semi graphitic
cathodes and graphitized cathodes with
VSD
Results Achieved/Results Achieved
Specific Power Consumption of cathodes:-
S.No Cathode Block
Power
Cons.(DC) UOM
1
Graphitized Cathode
with VSD 12700 Kwh/MT of
Hot Metal2 Semi graphitic A 13339
3 Semi graphitic B 13348
Benefits to organization:-
Tangible Benefits:
1. Energy saving-13500000 Kwh/Year (560
Kwh/TON)
2. Energy Cost saving-405 Lakh Rs/Year
Vedanta Limited, Aluminium - BALCO | 13
Project 2 - Energy reduction in Compressor and pump houses
Project Start Date : 01-01-2017
Project End Date : 03-02-2017
Problem Statement:- High energy consumption in utility area (Compressor and pump houses).
Data Collection
Specification of pumps.
Power consumption reports sampling.
Rectifomers temperature status.
Operation parameter of RPH.
Cooling temperature of all cooling towers.
Departmental Air flow measurement data.
Compressor air flow and pressure data.
Operation parameter of both compressor
houses
Data Analysis & Validation
Before project power consumption .
Feasibility analysis of automation of CT fan.
Temp. range margin available or not in system.
Parameters monitoring of cooling tower:(approach and
range).
Blade angle measurement and position and setting.
Analysis of pressure and flow variation of both compressor
house
Measurement of Motor & Pump efficiency.
Vedanta Limited, Aluminium - BALCO | 14
BEFORE PIPE LINE NETWORK
Hot Water line
Pump house
Cold Water line
RE
CT
IFIE
RS Cold Water Return line
PUMP HOUSE
CT#1 CT#2 CT#3
COLD WELL HOT WELL
V
V
AFTER PIPE LINE NETWORK
Hot Water line
Pump house
Cold Water lineR
EC
TIF
IER
S Cold Water Return line
MODIFICATION DRG FOR CLOSE LOOP OF COLD WATER PIPE LINE IN RPH 1
Grean pipe belongs to new modification with two valves
PUMP HOUSE
CT#1 CT#2 CT#3
COLD WELL HOT WELL
V
V
New system by pass the hot well
New close loop pipe line
HOT WELL
COLD WELL
Measures for energy reduction
To modify the cold water circulating line by Close loop system in Rectifier pump house.
Vedanta Limited, Aluminium - BALCO | 15
Power saving approx. 2.3 MWH/day by
stopping of two 45 KW pump
Water saving 36m3/day by reduction of evaporation
loss
Results achieved
Vedanta Limited, Aluminium - BALCO | 16
Cooling tower blade angle
adjustment for effic. increment
Impeller trimming before and after Cooling tower automation
Measures for energy reduction
Vedanta Limited, Aluminium - BALCO | 17
By close loop project : 2.3 MWH/Day (840 MWH/Year)
Total saving: 2995365 INR/ Year
CT automation= 345.6 KWH/Day (126144 KWH/Year)
Total saving : 378432 INR/Year
CT Effic. Increment = 22 KWH /Day (8030 KWH/Year)
Total saving : 24090 INR/Year
Compressor interconnection
Saving /Day : 9 MWH/Day (3285 MWH/Year)
Total saving : 9855000 INR/Year
Trimming of impeller
500 KWH/Day (182500 KWH/year)
Total saving : 5,47,500INR/Year
Grand total saving:13800387.00 INR
Valve operation has been reduced up to zero
level.
Improvement in Team work &
Communication.
After Integration we can run Pot line 1 with
Potline-2 Compressor House and vice versa in
case of complete tripping.
No need of reducing Pot line Amperage
during Compressor house major Shutdown.
Tangible Benefits Intangible Benefits
Uniqueness of closed loop projectSaving achieved = Mandays Reduction +50%
Chemical Reduction+ Water Consumption
Reduction+ Power Reduction
Horizontal deployment is going on various
areas :–Compressor pump house -1,Rectifier pump
house-2 ,Rodding pump house.
Benefits to organization:-Benefits to Organization
Vedanta Limited, Aluminium - BALCO | 18
Project 3 - Melting/Pre Heating of ladles using used oil & Reduction of Diesel consumption
.
Data Collected
Total Consumption & cost of diesel & used oil.
Practice and process
Temperature in ladles
Data Analysis ,Countermeasures
Use of electric preheater for preheating but -it required heavy expenditure.
Used of LPG gas for preheating but -it required heavy expenditure.
Pre heating time to be reduced but- impact quality (Non compliance)
Reduce the timing of melting but -the solid metal unable to melt.
Using of Used oil.
Validation & Results
Mixing 80:20 diesel and used oil ratio we got success.
Mixing 40:60 diesel and used oil ratio we faced problem in firing.
Mixing 45:55 diesel and used oil ratio we found awesome Result.
Project Start Date : 01-05-2016
Project End Date : 31-08-2016
Problem Statement:-Problem Statement-Higher consumption of Diesel in Melting and Preheating of ladles
Vedanta Limited, Aluminium - BALCO | 19
In Pre Heating Process
Before implementation
Diesel required for Pre Heating -2600 liters
Diesel Cost -2600X47= Rs122200
After implementation
Diesel required for Pre Heating -1170 liters
Diesel Cost -1170X47= Rs54990
Used oil required for Pre Heating -1430 liters
Used oil Cost -1430X15= Rs21450
Energy saving-64.8GJ
Total saving is 33540Rs in every Preheating of Ladles.
Overall benefits in a year 12X33540= Rs. 402480
In Melting Process
Before implementation
Diesel required for Melting -1000 liters
Diesel Cost -1000X47= Rs47,000
After implementation
Diesel required for Melting -540 liters
Diesel Cost -540X47=Rs25380
Used oil required for Melting -660 liters
Used oil Cost- ,660X15= Rs 9900
Energy saving-29.36 GJ
Total saving is 15480Rs in every melting of Ladle.
Overall benefits in a year 12X15480= Rs. 185760 .
Benefits to Organization
Intangible benefit & Uniqueness of project Usage & no discharge used of oil
Value out of waste.
Tangible Benefits
Vedanta Limited, Aluminium - BALCO | 20
Reduction in Specific water consumption 2.3 m3/MT (FY16) to 1.4 m3/MT (Lowest ever)(FY17)
Designated Consumer under PAT scheme for Aluminum Sector. PAT cycle -1 target over achieved by 0.088
TOE (awarded 22203 EScerts).
CDM project (Emission reduction) is registered with UNFCC w.e.f. 31st Dec-12 and valid till 31st Dec-22.
Implementation of SAP-EHS system
YearGHG emissions (Scope 1 + Scope 2)
in MT CO2 eq.
Metal Volume
(MT)
GHG emissions per Ton
of Al
2014 - 15 6089484 256636 23.7
2015 - 16 6116923 331526 18.5
2016 - 17 8263302 437578 18.9
GHG Inventorisation & Environment Management Initiatives
IMS Year No. of NC No. of Observation Open NC Open Observation
Balco 15-16 3 17 0 0
Balco 16-17 0 10 0 0
Status of EnMS (ISO 50001:2011) Audit Observation
Vedanta Limited, Aluminium - BALCO | 21
Installed 28 KW Grid connected Solar power plant & Planning for Installation of 5 MW Grid
connected Solar power plant.
Installation of transparent roof sheets & light bottles (liters of light) for harnessing sunlight at day
time inside office buildings, stores and containers to reduce lighting loads during day time has
saved 350 KWh/annum.
Rainwater harvesting is carried out as part of the Company’s commitment towards environment.
Planning to make Green building in township.
Action Plan for Installation of Solar lighting in Area
Utilization of Renewable Energy
SNo. AreaStart of
ProjectEnd of Project
Investment
( In Lakhs )
Payback
(Years)Status
1 Comprehensive Building01.06.2016 31.03.2017
37
28kwp system
installed2 DM Plant 25
3 Lab building
01.04.2017 30.10.2017
10
74 Canteen Plant-2 3
5 HSE office - Plant-1 20
6 Rectifier - Potline-101.11.2017 31.03.2018
257
7 Rectifier - Potline-2 10
Total 96 7
Vedanta Limited, Aluminium - BALCO | 22
Usage of Emulsion after treatment Qty. – 4320 MT/year.
SPL – SPL detoxification plant set up in under progress by M/s Star Regenerate-N-
Recycle LLP (Korba) and M/s GreenMac Technology Pvt Ltd (Raipur). (First
Company in India to do so)
SPL – Successful trail done for SPL Co-Processing at Ambuja Cement and Ultratech
Cement. Ambuja Cement Received the authorization for Regular Co-processing of
SPL.
)
Waste Management
WASTE TO WEALTH
Vedanta Limited, Aluminium - BALCO | 23
Green Supply Chain
Sl. No.Name of the
Vendor
Description of the Collaboration / energy reduction
initiative
1 Sumitomo For energy efficient cathodes
2 SGL For energy efficient cathodes
3 GAMI & AP Pot controller upgradation
4 SKF For energy efficient bearing & V-belts
5 GE Pot controller Analytics
6 Metsol For cathode air cooled taps
FY 15 – 183700FY 16 – 102500FY 17 – 87000
Ongoing Plans with Various Vendors
Additional measures for energy
reduction :-
Distribution of 5000no.s Energy booklet
in all schools of BALCO for increasing
awareness towards energy conservation.
Implemented Cardinal rules for energy
savings best operational practices.
Distribution of total-48717 Nos energy
efficient light fittings and fans through
Ujjala Scheme of EESL:-(May-16-June-
16) & (Jan-17 –Apr-17)
PLANTATION DRIVES.No. Initiatives Savings
1 BTAP Capacity Enhancement 396 GJ/Month
2 Bauxite Conversion Ratio 53 GJ/Month
3 Use of Higher Capacity Truck( from 16MT to 25MT) 1697 GJ/Month
4 Use of 12MT instead of 6MT ladles & Energy efficient
engine
116 GJ/Month
5 Use of GPS to identify shortest route
200 GJ/Month
6 Door to Door delivery initiative for issue of material from
stores
7 Transportation of finished goods in Container rake
8 Use of Re-Fuelling Vehicle
Vedanta Limited, Aluminium - BALCO | 24
Energy savings from Employee & Stakeholder Involvement
Details Unit 2014-15 2015-16 2016-17
FIP Projects No. 5 3 6
QCs / Kaizen Projects No. 25 15 18
Energy Savings Kwh 7664358 4375000 26892304
Benefits due to energy savings Rs. lacs 229 131 806
Vendus Meet to promote Energy Conservation
and Sustainability among Vendors
LED distribution Counter (EESL) at township
Vedanta Limited, Aluminium - BALCO | 25
ENERGY QUIZ
COMPETITION
ICQCC WINNER -GOLD
Place –Thailand Bangkok
ENERGY QUIZ
COMPETITION
Creating Awareness Among Stakeholders
Vedanta Limited, Aluminium - BALCO | 26
Title of ProjectName of the
Vendor
Per unit energy consumed%
ImprovementBefore Project After Project
Distribution of energy efficient light fittings
and fans through Ujjala & Pawan Scheme in
Balco township
EESL 72000 Kwh/day 68000 Kwh/day 5.55%
Heater optimization at Himadri Chemicals Himadri - - 9.2%
Implementation of Best Practices
Implementation of Idea generation portal & !DEA@BALCO APP for
generation of idea for All Balco & Contract employees.
Idea generated- 826
Idea implemented- 105
Idea under implementation-206
Initiatives taken by supplier has resulted in energy consumption reduction
Vedanta Limited, Aluminium - BALCO | 27
Awards and Accolades
Thank You!
Bharat Aluminium Company Limited
Korba, Chhattisgarh
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