Sterlite Industries Limited-Silvassa · CC Rod Power Reduction in Specific Electric Energy...

National Award for Excellence in Energy Management 2010:CII

Sterlite Industries India Ltd- Silvassa

Presented By:

Mishank Janveja(Energy Manager)

Sridhar K(HOD – Mechanical)

Excellence in Energy Management-2010

ª Company Overviewª List of Energy Conservation Projectsª Specific Energy Consumptionª Benchmarkingª Road Map for Futureª Innovative Projectsª Employee And Community Involvementª Energy Monitoring And Reportingª List Of Major Environmental Projectsª Awards & Certifications

Flow of Presentation


v Global industry positionv World’s largest integrated zinc mining and smelting company.v Currently 8th largest refined copper producer in the world.

v Aspirationv To become amongst the top 10 producers globally in

aluminum.v To become amongst the top 10 producers globally in iron ore.v To become a major power producer in India.

v Unique integrated model, including captive energy.v Low cost producer across all commodities.v 29,000 employees including 7,000 professionals.v Growth pipeline: 2003-2010 ~ $ 8.6 billion.v Robust balance sheet. Net cash of over $5.0bn.v FTSE 100 company, with current ranking of 56.

Group Overview


Silvassa ComplexRefinery : 196,000 tpaRod Mill : 160,000 tpa

Copper Mi nes

Group Overview & Operating Locations


REFINERY CC ROD

ANODE

CATHODE

ELETRO REFINING

CC ROD COIL

CASTING ROLLING

Process Overview


VISION AND MISSION


List of ENCON Projects


Projects with Zero investment

~ Reduction in De-Te Batch time by changing operating procedure.

Savings : 25.2KL of FO : Rs 0.543 Million

~ Reduction of CCV from 42 to 37mV.Savings : 0.173 million units : Rs 0.745 Million

~ Replacement of old mother blanks in cellsSavings : 0.173 million units : Rs 0.745 Million


Ø Replaced reciprocating compressor with twin lobe blower

Savings: 0.281 million units (Rs 0.98 Million)

: 15.9KL of FO (Rs 0.342Million)

Investment: Rs 0.5 Millions

Ø Installation of VFD for 90KW shaft furnace blower motor.

Savings: 0.2 million units (Rs 0.78Millions)


Ø Installation of Energy Efficient pumps.

Savings: 0.278 million units (Rs0.906Millions)


Projects with investment


Ø Weigh ladle cover modification to reduce one burner.Savings : 14.58T of LPG (Rs.0.5Million)


Ø Modification of 30Hp blower in ACP to reduce FO.

Savings : 60.39KL of FO (Rs.1.143Million)


Ø Launder modification to reduce LPG consumption.

Savings : 29.161T of LPG (Rs.1.149Million)


Ø Thermal insulation for Pickling tank and associated pipelines





Ø Steam vaporizer in place of Electrical for heating of LPG



Ø 100Hp and 30Hp pumps replacement with energy efficient pumps



Ø Refinery plant periphery covering with Tarpaulins





Ø Replacement of conventional chokes with electronic chokes in tube lights.



Ø Double pipe heat exchanger installed.



Ø Roof modification of furnace to increase charging area.



Ø Replacement of old and corroded bus bars in DC circuit





Total no of projects implemented = 17

ü Projects implemented without investments = 03

ü Projects implemented with investments = 14

Savings :

Electrical - 2.118 Million Units

Thermal - 227.36 KL of FO,

43.741 T of LPG

Total Investments made : Rs 2.69 Million

Total Savings Achieved : Rs 14.185 Million

ENCON Projects - Summary


Specific Energy Consumption


RFNY56%

ETP1%

ACP9%

PMB1%

CCRC23%

CCRP10%

RFNY ETP ACP PMB CCRC CCRP

ENERGY SHARE


Refinery Power

Reduction in Specific Electric Energy Consumption (kWh/MT)= -2.05%

Due to higher nickel content in the concentrate, there has been increase in power consumption.

Reduction in Specific Thermal Energy Consumption (KL/MT)= 3.08%


CC Rod Power

Reduction in Specific Electric Energy Consumption (kWh/MT)= 5.48%

Reduction in Specific Thermal Energy Consumption (KL/MT)= -0.03%


CATHODE National Benchmark ***

International Benchmark ***

Specific Energy Consumption Thermal 6.3 L/MT (Sterlite SVS) 6.93 L/MT

ChuquicamataSpecific Energy consumption Electrical

422.16 KWH/MT (Sterlite SVS)

343 KWH/MT Chuquicamata

CC ROD National Benchmark ***

International Benchmark ***

Specific Energy Consumption Thermal

33.52 Kg/MT (SterliteSVS)

NA

Specific Energy consumption Electrical

59.77 KWH/MT (Sterlite SVS)

NA

Benchmarking


q Replace LPG with LNG.q Fan less – Fin less cooling towers. q Hydrolyser installation in FO tank in ACP.q Expansion of Nickel Sulphate plant to reduce nickel concentration in electrolyte that result in less power consumption in refinery.q Installation of Energy Efficient pumps at locations as identified in energy audit.q Modification of the intermediate Bus bar to reduce the CCV to 34mVq Replacement of normal chokes with Electronic chokes for whole plant. q LED lamps installation in Street lights. q Utilization of waste like Residue Derived Fuel for Boiler from municipal waste.q Utilization of renewable resources like Solar Energyq Regular Energy Audits & identification of new projects.

Roadmap for the future


Innovative Projects


INNOVATIVE PROJECT - 1

Reduction in energy consumption by reduction in De-Te batch time

from 14.3 hrs to 10.9 hrs


STEAM

95 Deg. C

OnceTellurium

is BDL

2Cu+ + Te++ Cu2Te

ELECTROLYTE

To Cells

• 30 M3 solution is taken in a reactor.

• Reactor is filled with copper chips

• Temperature is raised to 95o C

• Tellurium reacts with the copper chips to form Insoluble copper telluride.

• At Tellurium is BDL, the solution is transferred to refining cells

• High De-Tellurisationcycle time resulting in more steam and power consumption.

PROCESS OF DE-TELLURISATION



STEAM

95 Deg. C

OnceTellurium

is BDL

ELECTROLYTE

To Cells

Recirculation from Decant and suction level

Before


Solution: Change the operating procedure , start recirculation of electrolyte from decant level instead of suction level.

Investment: Zero {only change in procedure }

Result : Reduction of the cycle time from 14.3 hour (avg) to 10.9 hour (avg) resulting in reduction of steam and power consumption


STEAM

95 Deg. C

OnceTellurium

is BDL

ELECTROLYTE

To Cells

Recirculation from Decant level only

After


Reduction in cycle time

Cycle time reduced from average 14.3 hr. to 10.9Hr.

Before After

Result


Reduction in steam consumption

Steam reduced from average 142 MT/Month to114MT/Month

Before After

Result


SAVINGSDescription Value Units

Reduction in steam consumption / Month 30 MTReduction in steam consumption / Year 360 MT

1 MT of Steam 0.07 KL of FOSaving of FO / Year 25.2 KL

Average Cost of FO / KL 21529 Rs.Total saving 0.54 Million Rs.

Intangible Benefits

1) Reduction in basket cleaning activity

2) Reduction in Hammering activity

3) Reduction in copper saving consumption


Emission Reduction (ER) = Quantity of Fuel saved x Calorific value x Emission factor

1 Ton of CO2 = 1 CER

Emission Reduction (ER) = 293.043 CER

Description Numerical Value Unit

Furnace oil Saving 90.57 Tons / Year

Calorific Value of FO 10000 Kcal / kg Emission Factor of FO 77400 Kg CO2 / TJ

Emission Reduction (ER) 293.043 Tons of CO2 / Year

Emission Reduction



Modification of 30Hp blower in Anode Casting Plant to reduce

Furnace Oil consumption


ACP PROCESS FLOWSPENT ANODES FROM

REFINERY

CHARGING

MELTING

REDUCTION

CASTING

METAL CHARGED THROUGH CONVEYOR CONTINUOUSLY

AFTER CHARGING HEATED UPTO 1140oC

REDUCTION REACTION USING FIREWOOD

ANODE CASTING

COPPER ANODES


PROBLEM STATEMENT:Ø The flame length of IV-A burner is less.Ø More time require to melt metal.Ø Air pressure require for V-A burner is higher than IV-A

burner.

Heat Flow in the Furnace


FURNACE OPENING

EXHAUST HOOD

CHARGING CONVEYOR

EXISTING SLIDING DOOR

Flame from Furnace


BURNERS

Burner Mounted on the Furnace


Replaced the “IV A” Burner with “V A” Burner that requires a static pressure of 1200 mm of water level .So , Modification in Blower was required .

What is Required ?

Burner function should give :

Ø Maximum flame travel within the furnace

Ø Minimum Flue gas losses

Ø Efficient atomization of Furnace oil

Idea for Solution :


By Fan Law:


Blower volume can be change by speed change that can be achieved by placing the specified pulley in both blower and motor side .

Speed Change By Pulley Method:

Old Blower Modified Blower


Specification Old Blower Modified

Capacity (CFM) 2400 2541

Static Pressure (mmWC) 1016 1242 Speed (RPM) 2900 3097

Motor Power (HP) 30 30

Motor Current (Amp) 28 38

Comparison of Old blower & Modified blower


Tangible and non tangible achievements:

Ø By Burner Replacement of Higher Capacity resultant FO saving 61.39 KL / annum .Ø Furnace capacity increased Resultant production Increased by 13 % Ø Reducing the amount of GHG, SOx, NOx emissions and other

pollutants. Ø Specific Consumption of FO reduced by 0.75 KL / MT of anode

production.


Description Numerical Value

Unit

Furnace oil Saving 61.39 Tons / Year

Calorific Value of FO 10000 Kcal / kg

Emission Factor of FO 77400 Kg CO2 / TJ

Emission Reduction (ER)

198.616 Tons of CO2 / Year

Emission Reduction (ER)= Quantity of Fuel saved x Calorific value x Emission factor

1 Ton of CO2 = 1 CER

Emission Reduction (ER) = 198.616 CER

Emission Reduction



Installation of VFD with battery backup for 90KW Shaft furnace blower motor in C C Rod Plant.


Holding Furnace Quenching

Roll Pass Profile

Auto Shear

BPU

Roughing Mill

Intermediate Mill

Finishing Mill

Launder

Slag Trap

ASARCO Shaft Furnace

Burners

CoilerCasting Wheel Properzi Mill

Cast Bar Cross section

CCR Plant Overview


Why Oxygen required in cc rod?

Oxygen is intentionally alloyed with copper to act asa scavenger for dissolved hydrogen and sulfur toform the gases H2O and SO2 in the molten copper.


What is Required ?

Level of Oxygen to be controlled by controlling the flow of air from blower. Earlier it was done by Damping method using M.O.V.

Installation of Variable frequency drive for Blower motor to vary the flow by varying the speed or motor.

Input power at partial load is more than theoretical value, which result in power loss.

Disadvantage of Damper Control.

Idea for Solution :



Equipment Installed.• Electronic 90KW Inverter Drive (VFD) Panel with Battery Backup as per

Scope of Supply suitable for 90kw AC motor.• Battery Bank of SMFB 75 AH, 12 volt, Exide Make,45 no.

Shaft Furnace Blower

Shaft Furnace Drive Panel

Battery Bank for Backup Power


Saving CalculationsDescription Numerical Value Unit

Avg. units consumed / MT before VFD installation

62.38 kWh/MT

Avg. units consumed / MT after VFD installation

60.43 kWh/MT

Saving / MT 1.95 kWh/MT

Avg. production / day 270 MTAnnual Saving 192173 kWh

Savings 0.78 Million Rs.Non tangible benefits:1) Uninterrupted power supply even during power changeover from grid to DG.2) Easy control of oxygen level in furnace.3) Reduction in rejection of coil because of oxygen variation.


Replication of Best Practices


The FLUX maxiox™ (β-series) V 2.0 is a magnetic device which generates a magnetic field that is rendered exactly perpendicular to the fuel flowing through the fuel line on whichit is installed. This magnetic field is scientifically designed to impart certain physical changes in the fuel thereby causing the fuel to burn more efficiently

Installation of Flux Maxion in LPG line of CCR plant


LPG Consumption DetailsAfterBefore

LPG KG/MT

29.5030.0030.5031.0031.5032.0032.5033.00

Jan Feb Mar April May June

LPG KG/MT

Result in saving of LPG Consumption by 5 % & resulting in saving of 70 lakhs / year

Greenhouse gas emissions factors for propane are 62.7 kg CO2/ mBTUor 1.55 kg of CO2 per litre or 73.7 kg / GJ


Environmental Projects


1)Conversion of FO fired boiler to Briquette fired Boiler

Environmental and Social benefits of BiomassØ Complete substitution of FO by briquette resulting in saving of 1670 KL of FO i.e. total savings of 2.57crores annually by the substitution of FO.Ø Reduction in flue gas temperature from normal 220°C to 140 °C resulting in 4 % increase in thermal efficiency.Ø Reduced emission of Green House Gases.ØReducing the amount of GHG, SOx, NOx emissions and other pollutants. Ø Biomass recycles the amount of CO2 in the system as it effectively generates the same amount of the CO2 it absorbed during its growth stage. Hence net CO2 emission is zero during its combustion.Ø Sulphur content nil against 4% in Furnace Oil.ØAsh generated will be used to make bricks. Hence reduced soil erosion


Employee Involvement


1) Ideas @ Sterlite : Idea submitting platform for company employee.

2) My Ideas : Idea submitting platform for contract employees.

3) ACE-4000 : Achieving Cost Excellence -4000 is a project for reducing COP by implementing Energy Saving projects. Total of 11 projects are running under ACE-4000 in Silvassa unit.

4) TQM: Completed 9 phases successfully and 10th phase under progress. Each TQM project is directly or indirectly related to Energy Saving.

5) “Energy Month” is celebration every year with specific theme. Quiz, poster competition, slogan competition etc. are organized to increase awareness about energy conservation in employees.

Employee involvement


Suggestion at Ideas@SterliteWork Place in Lotus Notes_________Idea Originator

Intimation of same toI@S coordinator on Lotus Notes

Review of Suggestion

______Idea reviewcommittee

Suggestion approved forImplementation

Test for feasibility (Trial If required)

Suggestion Documented

Trial Successful

Implementation of suggestion __________Implementation Team / Dept I@S Coordinator

Implementation complete

Review of Implementedidea for benefitsand Sustainability

______________Ideas audit team.

Confirmation from audit teamfor successful implementation of idea.

For successful implementedRecognition and

Appreciation in quarterly Function.

IDEA ORIGINATION

AUDIT & RECOGNITION

IMPLEMENTATION

REVIEW & DOCUMENTATION

Ideas Mechanism


IAS through Lotus notes


174

433534

1015

87203

115

345

0

200

400

600

800

1000

1200

2006-07 2007-08 2008-09 2009-10

No

. o

f Id

eas

Ideas Posted

Ideas Implemented

Ideas for the years


Suggestion Scheme for contract employee

Recognition Myideas@sterlite

Creativity Meet for company & contract employee


Energy Monitoring & Reporting


ROLE OF ENERGY MANAGER

q Dedicated Energy Manager is appointed and functionally reports to

Head Engineering.

q Monitors daily consumption of Energy, prepares monthly Energy

report and reviews the same in front of Head-Operations.

q Coordinates with External party for Energy Audit and Identification

of Energy Conservation Projects.

q Resource allocation & Coordination with functional departments to

implement Energy Conservation projects.


REPORTING STRUCTURE


qWhole Plant is divided into 6 areas and Energy Consumption is monitored on a daily basis

q Centralized energy monitoring & data acquisition system (SCADA) for monitoring power consumption in the plant.

q Energy norms are fixed for all the equipments & any variation is monitored on a daily basis

q Energy report is getting prepared by the Energy Manager and isgetting reviewed by the Head operations in presence of SectionalHeads both on daily and monthly basis

q The Energy report consists of Energy Share, Power distribution, Fuel Distribution, Specific Consumption, Trend analysis, Concerns and action plan for the next month.

ENERGY MONITORING SYSTEM


ENERGY MONITORING

Total Energy Distribution

54%

12%

34%

Power FO LPG/PROPANE

ENERGY SHARE

MONITORING FORMAT

Mar'10 Prod (MT)

Power (GJ)

Fuel (GJ)

Total (GJ)

Sp.Cons.(GJ/MT)

Sp.Cons.Elec

Sp.Cons.Therm

RFNY 15909 26638.99 6499.09 33138.08 2.08 1.67 0.41ETP 600 146.28 108.83 255.11 0.43 0.24 0.18

ACP 2166 173.42 5602.34 5775.76 2.67 0.08 2.59PMB 42.78 643.37 134.20 777.57 18.18 15.04 3.14

CCRC 8129 1906.17 12414.60 14320.78 1.76 0.23 1.53

CCRP 4697 1177.65 7786.61 8964.26 1.91 0.25 1.66


ENVIRONMENTAL PROJECTS

Ø Rain water harvesting in the plant. (Investment - 9.6 Lakhs)

Ø Continuous monitoring of air, water and stack Quality.

Ø Reduction in air pollution by introducing scrubbers. (Investment - 3.5 Lakhs)

Ø Installed Sewage Water Treatment facility. Treated water is being used for gardening purpose. (Investment - 2.5 Lakhs)

Ø Installed air pre heater in the boiler to reduce fuel consumption. (Investment - 5.5 Lakhs)

Ø Green belt development in and around the plant.

Ø Installed Acetylene Soot Collection System installed in CCR to improve working Environment. (Investment - 5.6 lakhs)


ENVIRONMENTAL PROJECTS

Ø Installation of Air Ventilators in Refinery & CCR. (Investment - 3.23 Lakhs)

Ø Installed Recuperator in ACP to preheat the air reducing fuel equivalent to 53.89 KL of FO annually ( Investment – 3 Lakhs)

Ø Briquette based boiler installed reducing the amount of GHG, Sox, NOx emissions and other pollutants . Sulfur content nil against 4% in FO. Reduced flue gas temperature from normal 220 C to 140 C resulting 4 % increase in thermal efficiency ( Investment – 38 Lakhs)


§ 15 hand pumps donation in Chinchpada village

§ Malaria Awareness program for Chinchpada Villagers

§ Support Vasona primary School Hygiene & Sanitation

§ Contributed for Common Marriage program organized for Tribal and Adavasi

§ Traffic Awareness program - in Vasona School

§ Blood Donation Camp organized

§ Identity Cards to School Students

§ Annual Sports Meet for Vanvasi Kalyan Ashram

§ pulse polio immunization drive was declared by Health depart of DNH

§ Shala Pravesh Mohostav to encourage new admission for primary education

§ Extending Mobile Dispensary visit o Chinchpada

CSR INITIATIVES – REACHING OUT


AWARDS AND ACCOLADES

2009-2010v Qualified for Super Platinum Corporate award from IMEA.v Performance Excellence Trophy from RBNQA v ISO 9001, ISO14001 and OHSAS 18001 re-certification by DNV.v Re- Accreditation Laboratory Management system (ISO 17025:2005), by

NABL.v Certification for Information Security Management System

( ISO 27001:2005) from United Kingdom Accreditation Service (UKAS). v Received RSCS certification from UL INDIA.v International Star award for Quality – Qualified for Gold category.v Qualtech Innovation award – Certification of Merit for 1 project.v Qualified as finalist in ASQ Team Competition.v Received Merit award at “Safety Innovation award 2009” from IEI, New

Delhi.v CII - Excellence Awards in Water management-2009v CII - Energy Efficient Unit Award -2009v 2nd prize at “ISTD award for Innovative training practices”-2009v Received 1 Special Award 2 Merit Award & 1 Corporate at INSSAN



Let us join our hands together to save our Planet


Thank You

Sterlite Industries Limited-Silvassa · CC Rod Power Reduction in Specific Electric Energy...

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