CII Excellence in Energy Management Award

Transcription

1 Care Entreprene urship Trust CORE VALUES Respect Innovation CII Excellence in Energy Management Award Integrity Excellence Vision : To be a World Class Integrated Aluminium & Power Producer Generating Sustainable Value for All Stakeholders

2 BALCO OVERVIEW Bharat Aluminium Company (BALCO) is the 1st PSU in India s Aluminium sector incorporated in One of the first disinvestments of the Government of India & it is 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, with 2010 MW power generation capacity and 5.7 LTPA Aluminium Smelting capacity at Korba Complex. Plant Overview (CPP 540MW) Number of units 4 Capacity of each unit 135 MW Make: Harbin Spec: Single drum, Natural Circulation, Pulverized Fuel fired, Single Reheat, Balance Draft, and Tangentially Corner Fired Make: Dongfang Spec: Reheat, Double steam exhaust, two casing condensing steam turbine Vedanta Limited, Aluminium - BALCO 1

3 PROCESS FLOW : POWER PLANT CPP 540 PLANT PROCESS FLOW DIAGRAM COAL PILE TO ATMOSPHERE COALYARD Ф=80000 T AIR FROM ATMOSPHERE SWITCH YARD TRAFO 220 KV step up OLTC Forced Air Cooled G 135MW 13.8 kv INDUCED COOLINGTOWER Range=8.4 Approach=4 CRUSHER HOUSE Ф=4*1000 T/H COAL BUNKERS (4*4 Nos) Ф=496 T COAL FEEDERS, Ф= 37 t/h POWE R COAL MILLS(BOWL & ROLLER) Ф=75 t/h STEAM TURBINE (135MW)(30+1 STAGE) HIP/LP,Double Exhaust, Double Casing, Condensing Steam Turbine CONDENSER (-90kpa) Cooling Area=8500 m3 No. of Tubes No CW PUMP(2 Nos.) Flow=10800 M 3 /H COAL SUPERHEAT STEAM Pressure=13.7Mpa Temperature=537 C 44 C PA FANS(2 Nos) T FLOW=196 t/h Seal Air Fan PRIMARY AIR GAS 290 C BOILER (PF, Corner Fired, single reheat) Pressure=14.29Mpa; Temperature=540 C;Flow= 460 T/h FEED WATER Ksc, 245 C HP HEATER, 2 Nos 171 C BOILER FEED PUMP(2Nos.) O/L Pr= Ksc (max) Maximum Flow=560T/H DEAERATOR & FST Pr.=0.709Mpa, 140m3 141 C 169 C LP HEATERS, 4 Nos. CONDENSATE EXTRACTION PUMP (2) Nos. of Stage- 5, O/L Pr. =18.91 Ksc; FLOW=373 m 3 /h FD FANS(2 Nos), FLOW=342 t/h AIR PRE HEATER, 2 Nos SEC AIR 300 C FLUE GAS 340 C BOTTOM ASH ID FANS(2 Nos), FLOW= 855 t/h CLEAN GAS ESP (2*5 Fields) U#2 (1 st 2 field BAG FILTER) 147 C FLY ASH SLURRY PIT ASH SLURRY SLURRY PIPE LINES ASH DEWATERING BIN, 3 Nos MIXING TANK, 2 Nos GEHO, 2Nos (208m3/hr) ASH DYKE STACK H=275 mtr. FLY ASH SILO (2 Nos) ASH CONDITIONER COAL COAL WITH HOT PA FLY/BOTTOM ASH SUPERHEATED STEAM CONDENSATE WATER COLD AIR HOT AIR COOLING WATER Vedanta Limited, Aluminium - BALCO 2

4 ENERGY OBJECTIVES EnMS Objective (FY 18) Reduction in Specific Coal Consumption(SCC) from 720 gms/ kwhr to 707 gms/ kwhr Reduction in Specific Oil Consumption (SOC) from 0.35 ml/ kwh to 0.28 ml/ kwhr Reduction in Auxiliary power consumption (APC) from 10.11% to 9.62% EnMS Vision (FY 21) Reduction in Specific Coal Consumption(SCC) to 690 gms/ kwhr Reduction in Specific Oil Consumption (SOC) to 0.22 ml/ kwhr Reduction in Auxiliary power consumption (APC) to 9.30% Vedanta Limited, Aluminium - BALCO 3

5 ENERGY POLICY & CERTIFICATION S. No Description Certification 1 Quality management system ISO 9001: Environment Management System 3 Occupational Health & Safety Management System ISO 14001:2004 OHSAS 18001: Energy Management System ISO 50001: Asset Management System ISO 55001: International Automotive Task force TS Vedanta Limited, Aluminium - BALCO 4

6 ENERGY CONSERVATION JOURNEY & REVIEW MECHANISM 2015 Turbine Steam Path Audit 2016 Energy Efficient Drives 2017 Ultra High Filtration System 2018 CW Pump Trimming & Coating, Replacement turbine seals 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 Saving, Cost Reduction, Sustainable Operation Benchmarking Innovation Awareness Involvement Certification & Awards Vedanta Limited, Aluminium - BALCO 5 Energy Excellence Model

7 BENCHMARKING KPI UOM BALCO CPP 4x135 MW JSG 9x135 MW LAPANGA 6x150 MW KSK WARORA 4x135 MW JSW TORANGALLU 2x130 MW NALCO 10x120 MW <300 MW PLF % PAF % APC % Heat Rate Kcal/ KWh Vedanta Limited, Aluminium - BALCO 6

8 INNOVATIVE PROJECT 1 - TURBINE HPDE & LPDE CORRECTION Why: How: To maintain MS and RH steam parameter at rated value. Modification at front pedestal & HP/LP rotor coupling Spacer plate width reduced by 2mm LPDE reduced from 7.5 to 4.5 mm Front Pedestal HIP Turbine LP Turbine Gen & 4 5 Expansion Increased from 10 mm to 20mm 1. HIP Front Pedestal (MOP, Bearing -1) 2. 2 nd Pedestal (HIP LP Rotor Coupling, 2 no Journal Bearing, 2No Thrust Bearing) 3 &4. 3 rd Pedestal (LP Generator Coupling, 3 rd Journal, 4 th Journal Bearing, Turning Gear) 5. Generator Rare Pedestal (5 th Journal Bearing & Excitation System) Vedanta Limited, Aluminium - BALCO 7

9 TURBINE HPDE & LPDE CORRECTION HP Turbine Front Pedestal Modified Lub oil piping Before After welded Joint between header and Bearing pedestal Flexible joint between header and Bearing pedestal Vedanta Limited, Aluminium - BALCO 8

10 mm mm SAVING- TURBINE HPDE & LPDE CORRECTION HPDE LPDE Result: During turbine major overhauling, LPT Bottom casing and front bearing pedestal is removed and its contact surface finishing for smooth expansion of casing Bellow installation in pipe for lube oil inlet & outlet for main oil pump to facilitate the free movement of front pedestal. o C Main Steam Temperature o C Reheat Steam Temperature Description Savings Unit Temperature Utilisation in MS & RH Cycle 15/60 Deg C Impact on Specific Coal Gms/KW Consumption hr Direct saving in Coal Consumption MT / Year Cost Lacs in INR Vedanta Limited, Aluminium - BALCO 9

11 INNOVATIVE PROJECT 2 - APH PA SECTOR MODIFICATION Why: How: To reduce primary air pressure difference across Air Pre Heater. By reducing the SA side opening & modification of PA sector plate Vedanta Limited, Aluminium - BALCO 10

12 INNOVATIVE PROJECT 2 - APH PA SECTOR MODIFICATION Degree of opening for PA section has been increased from 50 deg to 60 deg Degree of opening for SA section has been decreased from 130 deg to 120 deg New main 20 degree sector plate were erected in both Hot & Cold end center sections APH Primary Air side Old Sector Plate APH Primary air side new sector plate Vedanta Limited, Aluminium - BALCO 11

13 mm of H 2 O mm of H 2 O SAVING - APH PA MODIFICATION APH A PA Differential Pressure Result: PA DP across APH reduced to 180 mm H 2 O from 325 mm H 2 O after modification Additional PA fan stopped. 350 APH B PA Differential Pressure Specific Power Consumption Power Saving Unit Stoppage of PA fan 6.50 MU/Year Cost Saving in INR Lacs/Year 0 Vedanta Limited, Aluminium - BALCO 12

14 T/Hr Why: How: INNOVATIVE PROJECT 3 - REDUCTION IN RH ATTEMPERATION To reduce attemperation in hot reheat steam Removal of outer loop of final reheat panel. RH tube loop removed and made dummy towards header side RH Attemperation Spray April May June Description Savings Unit Reduction in RH Attemperation Spray 8 T/Hr Impact on Specific Coal Consumption 1.89 Gms/KWhr Direct saving in Coal Consumption MT / Year Cost Saving Lacs in INR Vedanta Limited, Aluminium - BALCO 13

15 Utilization of heat in flue gas: Utilization of waste heat from the flue gas leaving the boiler by installing additional tubes at the bottom bank of economizer, thereby achieving 12 o C reduction of flue gas temperature at APH inlet after modification. Description Savings Unit Reduction in Exit Flue gas temperature of APH 8 deg C Old tubes New tubes Old tubes Impact on Specific Coal Consumption 2.27 Gms / KWhr Direct saving in Coal Consumption 7581 MT Cost Saving Lacs in INR Vedanta Limited, Aluminium - BALCO 14

16 MAJOR ENERGY CONSERVATION PROJECTS S.No Title of Project Saving Lacs / Annum in INR 1 Reduction in O2 % in flue gas (0.29MU) 82 2 Improvement in condenser vacuum(0.66mu) 3 Power consumption reduction in Compressors(0.067MU) Improvement in belt conveyor utilization factor(0.2mu) 54 5 Installation of W LED tube lights in place of 40 W conventional tube lights through EESL scheme (0.91MU) Installation of Motion Sensors for lighting control in Washrooms / Conference room 2.7 (0.09MU) 7 Installation of no's W LED Street lights in place of 250W HPSV (0.3MU) 9 8 Installation of Led Down-lighter lights in Canteens (0.04MU) 1.2 Total Vedanta Limited, Aluminium - BALCO 15

17 TRENDS PERFORMANCE IN PREVIOUS YEARS SCC & APC Reduction in Specific Coal Consumption (Gms/KWhr) Reduction in Auxiliary Power Consumption (Kwhr) Modification done to reduce Turbine LPDE for increasing MS & Reheat Steam temperature. Addition of extra coil in economiser to reduce exit flue gas temperature Installation of additional CT cell to reduce cooling water inlet temperature to condenser Installation of VFD in FD & ID fans. APH modification done to reduce PA DP and stop one PA fan. Logic provided in DCS to stop Standby Mill LOP after 30min if mill is not taken in to service. Vedanta Limited, Aluminium - BALCO 16

18 TRENDS PERFORMANCE IN PREVIOUS YEARS SOC & SWC Reduction in Specific Oil Consumption (ml/kwhr) Improvement in availability of boiler & turbine auxiliaries Deaerator preheating Oil gun Igniter length adjusted to increase gun reliability. Oil gun nozzle plugging done to increase operating pressure of oil system and hence impacting atomization 2.57 Reduction in Specific Water Consumption Vedanta Limited, Aluminium - BALCO 17 Replacement of drift eliminators Optimization of CT blowdown Zero discharge pit for drainage water Utilization of ETP Water in AHP & Fire Fighting water Utilization of storm water Plant Drain line modification to ensure zero discharge and 100 % utilization of drain water

19 FUTURE TARGETS SPECIFIC COAL CONSUMPTION 707 SCC (Gms/Kwh) Action Plan Turbine seal replacement Dynamic classifier Operational changes to be discussed and implemented. Condenser tube bundle replacement Arresting air ingress in boiler Reduction in super heater attemperation FY FY FY Vedanta Limited, Aluminium - BALCO 18

20 FUTURE TARGETS SOC & APC Action Plan Reliability improvement of boiler & turbine auxiliaries Oil gun nozzle modifications to be done to minimize oil consumption during startup Feasibility study to be done for use of plasma ignition Operational changes to be discussed and implemented Action Plan Inspection and replacement of all Boiler feed pumps cartridge to be done. All lighting in open areas to be replace by timer control or based on sensor control. Reduction in compressed air consumption Vedanta Limited, Aluminium - BALCO 19

21 EMPLOYEE INVOLVEMENT TOWARDS ENCON Vedanta Limited, Aluminium - BALCO 20 ENERGY MONTH PRIZE DISTRIBUTION

22 ENVIRONMENT MANAGEMENT INITIATIVES Reduction in BALCO Specific water consumption 2.3 m3/mt (FY16) to 1.4 m3/mt (Lowest ever)(fy17) Balco has won the "FAME Excellence Award 2016" in Environment Protection - Gold Award Balco has been awarded for being the Winner in the LARGE SCALE Manufacturing category [Above 3000 employees] of Safety, Health & Environment Awards from the Confederation of Indian Industry. Status of EnMS (ISO 50001:2011) Audit Observation IMS Year No. of NC No. of Observation Open NC Open Observation CPP CPP ESP Bag Filter Retrofitting Design ESP had 5 Fields Ammonia Dosing was in practice to increase the conductivity of fly ash Average SPM was more than 100mg/Nm3 Vedanta Limited, Aluminium - BALCO 21 In ESP, last three fields were replaced with fabric filters Ammonia dosing stopped in all units Average SPM is below 25 to 30mg/Nm3

23 GHG INVENTORISATION Tangible Benefit : Cr of Indian rupees till Mar 2017 Environmental Benefit : Saving of MT of Coal till Mar : Reduction in Greenhouse gas emission of tco 2 e. Actual unit generation at 69% PLF for FY Million unit Coal SCC of MT Coal SCC of MT Total coal saving MT Coal price FY per MT 2787 Rs Total saving Cr Rs GHG emission GHG SCC of tco 2 e GHG SCC of tco 2 e Total reduction tco 2 e Vedanta Limited, Aluminium - BALCO 22

24 ENERGY MONITORING SYSTEM Process Score Card APC & SCC Variance 1. Installation of Online EMS system 2. All relevant energy data is captured from these resources at regular intervals by PDHR data.. 3. Integrated energy monitoring system in place PERFORMANCE INDICATORS Unit ON DATE BP Actual Gross Generation MU Gross Generation MW PLF % 71.68% 95.41% Aux.Cons. (MU) Aux Cons. % 13.02% 9.82% Coal consumption MT SCC (based on actual GCV) (gms/kwh) LDO consumption KL HFO consumption KL Total Oil Consumption KL Online EMS System SOC (ml/kwh) Vedanta Limited, Aluminium - BALCO 23

25 ENVIRONMENTAL & RENEWABLE ENERGY PROJECTS Use of Drain water in AHP:- By connecting drain line to bottom ash slurry Pit. By this modification, we are able to utilise rain water. Rainwater harvesting is carried out as part of the Company s commitment towards environment 100% utilization of ETP discharge water in AHP, Fire fighting and in gardening. Recycling of plastic waste generated after CT cell fills replacement. Installed 28 KW Grid connected Solar power plant & Planning for Installation of 5 MW Grid connected Solar power plant. Planning to make Green building in township Action Plan for Installation of Solar lighting in Area SNo. Area Start of Project End of Project Vedanta Limited, Aluminium - BALCO 24 Investment ( In Lakhs ) 1 Comprehensive Building DM Plant 25 Payback (Years) 3 Lab building 10 4 Canteen Plant HSE office - Plant Rectifier - Potline Rectifier - Potline Total Status 28kwp system installed Segregation biodegradable & Non biodegradable waste Real Time SPM data monitoring & acquisition Fire fighting water line rerouting from underground to overhead line Drain water line connected to Ash Slurry Pit

26 WASTE MANAGEMENT Zero Discharge Project: 100% utilization of ETP water for water washing in AHP & boiler area. CT Over flow reduction/ blow down optimisation & maintaining COC above 8.0. Storm water drain line modification to ensure zero discharge and 100 % utilization of drain water. Ash Utilization: Ash utilization increased from 30% to 40% 1. Chotia mines backfilling : 10% 2. Ash dyke rising : 20% 3. Road & Brick : 5% 4. Low lying area backfilling : 5% Vedanta Limited, Aluminium - BALCO 25

27 GREEN SUPPLY CHAIN Usage of domestic coal instead of imported coal. Increased capacity of coal trucks from 20 Ton to 32 Ton. Unloading of coal through Truck Tippler project. Use of aluminium boxes in place of wooden boxes by local vendors Door delivery of stores material. Usage of energy efficient SKF bearings PLANTATION DRIVE FY FY FY Additional measures for energy reduction :- Distribution of 5000nos 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 Nos energy efficient light fittings and fans through Ujjala Scheme of EESL:- (May- 16-June-16) & (Jan-17 Apr-17) Vedanta Limited, Aluminium - BALCO 26

28 ENERGY SAVINGS FROM EMPLOYEE & STAKEHOLDER INVOLVEMENT Details Unit FIP Projects No QCs / Kaizen Projects No Energy Savings Kwh Benefits due to energy savings Rs. lacs Vendus Meet to promote Energy Conservation and Sustainability among Vendors LED distribution Counter (EESL) at township Vedanta Limited, Aluminium - BALCO 27

29 Vedanta Limited, Aluminium - BALCO 28 AWARDS AND ACCOLADES

30 IMPLEMENTATION OF BEST PRACTICES Implementation of Idea generation portal APP for generation of idea for All Balco & Contract employees. Idea generated Idea implemented Idea under implementation Initiatives taken by supplier has resulted in energy consumption reduction Title of Project Name of the Vendor Before Project Per unit energy consumed After Project % Improvement Distribution of energy efficient light fittings and fans through Ujjala & Pawan Scheme in Balco township EESL Kwh/day Kwh/day 5.55% Vedanta Limited, Aluminium - BALCO 29

31 Thank You! Bharat Aluminium Company Limited Korba, Chhattisgarh Follow us: