CII Award for Excellence in Energy Management

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

2 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 1

3 Process Flow Aluminium Production FTP To the air Captive Power Plant Utilities Air DC Power Enriched Al2O3 Fume Fumes after Dry scrubbing Stack Technology Provider Potline1 GAMI (320KA), Potline2 GAMI (340KA) Prebaked Rodded Anode Crust Bath Butts Cryolite, Soda, ALF3 Bamboo Liquid Al Carbon Electrolyte cell (Pot) Central Store - Electrical Power as part of COP 38% Cast house 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) - Electrical Power as part of energy consumption 98% Vedanta Limited, Aluminium - BALCO 2

4 Certifications, Energy Policy and Objectives ENERGY OBJECTIVES (FY18) : 1. Reduce Net AC Power consumption from to KWH/Mt-Al 2. Reduce Auxiliary Power Consumption from 438 to 417 KWH/MT-Al ENERGY OBJECTIVES (Vision FY21) : 1. Reduce Net AC Power consumption to KWH/Mt-Al 2. Reduce Auxiliary Power Consumption to 380 KWH/MT-Al S. No Description Certification 1 Quality management system ISO 9001: Environment Management System ISO 14001: Occupational Health & Safety Management System OHSAS 18001: Energy Management System ISO 50001: Asset Management System ISO 55001: International Automotive Task force TS Vedanta Limited, Aluminium - BALCO 3

5 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 Saving, Cost Reduction, Sustainable Operation Benchmarking Innovatio n Awareness Involveme nt Certific ation & Awards Vedanta Limited, Aluminium - BALCO 4 Energy Excellence Model

6 Global benchmarking & Energy Conservation Vision 2021 Energy Consumption (GJ/MT) FY 14 FY 15 FY 16 FY 17 Indian Benchmark International Benchmark FY 18 FY 19 FY 20 FY 21 S. No. Major Projects / Action Plan for Vision FY 21 Power Saving Unit Vedanta Limited, Aluminium - BALCO 5 Target 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 Kwh/MT Feb-18 4 Up gradation of Pot-control system in Pot-line Kwh/MT May-18 5 Increase in Pot-line Current Efficiency from 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

7 Potline DC Sp/ Power Benchmarking Vedanta Limited, Aluminium - BALCO 6

8 Major Energy Conservation Projects S.No Vedanta Limited, Aluminium - BALCO 7 Title of Project Annual Energy Saving Million KWH Investment Million INR 1 Energy reduction in Utility area (Compressor and pump houses) Use of 100% Graphitized Cathode (done in 98 pots) 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 Rodding 2-1. Minimize idle running hours in all bet conveyors,2.-installation of timers in all De-dusting unit,3.induction Furnace Process Optimization Installation of W LED tube lights in place of 40 W conventional tube lights through EESL scheme Installation of Motion Sensors for lighting control in Washrooms / Conference room 7 Installation of no's W LED Street lights in place of 250W HPSV Installation of LED Down-lighter lights in Canteens

9 Major Energy Conservation Projects Contd. S.No Vedanta Limited, Aluminium - BALCO 8 Title of Project Annual Energy Saving Million KWH Investment Million INR 9 Close loop provision in Compressor & Rectifier pump house -1 & One compressor Air end up-gradation Conversion of Lighting load to Solar Installation of VFD for Cold well pumps in ACH NCRM AC Plant cooling water system to be merged with RCW line Use of Induction Cooktop in place of Nichrome based heaters in Canteens TOTAL %Investment for Major Energy conservation projects on Turnover FY Project Description Investment (Rs. Crs) Turnover (Rs. Crs) % Investment on Turnover % Graphitized Cathodes % Pot Controller upgradation and 100% Graphitized Cathodes % Cathode Air cooled taps and 100% Graphitized Cathodes %

10 Project % Graphitized Cathode with variable slot depth design Project Start Date : Project End Date : 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. Specific Power Consumption of Semi graphitized cathodes:- S No. Cathode Block Power Cons. (DC) 1 Semi graphitic A Semi graphitic B Semi graphitic C UOM KWH/MT of Hot Metal Vedanta Limited, Aluminium - BALCO 9

11 Uniqueness of the project 3D graphical representation of the VSD Collector bar Slot VSD C 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. Vedanta Limited, Aluminium - BALCO 10

12 Data Analysis, Countermeasures & validation CVD (in mv.) CVD Trend of different cathodes Age (in Days) Wear rate comparison:- S No. Cathode Block Max wear Predicted life rate(mm) (Days) 1 Graphitized cathode with VSD 68, Semi graphitic A 139, Semi graphitic B 145, Vedanta Limited, Aluminium - BALCO 11

13 Results Achieved Results Achieved/ 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 Specific Power Consumption of cathodes:- S.No Cathode Block Power Cons.(DC) UOM 1 Graphitized Cathode with VSD Kwh/MT of 2 Semi graphitic A Hot Metal 3 Semi graphitic B Vedanta Limited, Aluminium - BALCO 12 Tangible Benefits: Benefits to organization:- 1. Energy saving Kwh/Year (560 Kwh/TON) 2. Energy Cost saving-405 Lakh Rs/Year

14 Project 2 - Energy reduction in Compressor and pump houses Project Start Date : Project End Date : 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 13

15 Measures for energy reduction RECTIFIERS V RECTIFIERS V To modify the cold water circulating line by Close loop system in Rectifier pump house. BEFORE PIPE LINE NETWORK AFTER PIPE LINE NETWORK MODIFICATION DRG FOR CLOSE LOOP OF COLD WATER PIPE LINE IN RPH 1 CT#1 CT#2 CT#3 CT#1 CT#2 CT#3 New close loop pipe line COLD WELL HOT WELL COLD WELL HOT WELL PUMP HOUSE Hot Water line PUMP HOUSE Hot Water line New system by pass the hot well Pump house Pump house Cold Water line Cold Water Return line Cold Water line Cold Water Return line HOT WELL COLD WELL Vedanta Limited, Aluminium - BALCO 14 Grean pipe belongs to new modification with two valves

16 Results achieved Power saving approx. 2.3 MWH/day by stopping of two 45 KW pump Water saving 36m3/day by reduction of evaporation loss Vedanta Limited, Aluminium - BALCO 15

17 Measures for energy reduction Impeller trimming before and after Cooling tower automation Cooling tower blade angle adjustment for effic. increment Vedanta Limited, Aluminium - BALCO 16

18 Benefits to OrganizationBenefits to organization:- Tangible Benefits By close loop project : 2.3 MWH/Day (840 MWH/Year) Total saving: INR/ Year CT automation= KWH/Day ( KWH/Year) Total saving : INR/Year CT Effic. Increment = 22 KWH /Day (8030 KWH/Year) Total saving : 24090INR/Year Compressor interconnection Saving /Day : 9 MWH/Day (3285 MWH/Year) Total saving : INR/Year Trimming of impeller 500 KWH/Day (182500KWH/year) Total saving : 5,47,500INR/Year Grand total saving: INR Vedanta Limited, Aluminium - BALCO 17 Intangible Benefits 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. Uniqueness of closed loop project Saving 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.

19 Project 3 - Melting/Pre Heating of ladles using used oil & Reduction of Diesel consumption. Project Start Date : Project End Date : Problem Statement:-Problem Statement-Higher consumption of Diesel in Melting and Preheating of ladles 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. Vedanta Limited, Aluminium - BALCO 18

20 Benefits to Organization In Pre Heating Process Tangible Benefits Before implementation Diesel required for Pre Heating liters Diesel Cost -2600X47= Rs After implementation Diesel required for Pre Heating liters Diesel Cost -1170X47= Rs54990 Used oil required for Pre Heating 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 In Melting Process Intangible benefit & Uniqueness of project Usage & no discharge used of oil Value out of waste. Before implementation Diesel required for Melting 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 GJ Total saving is 15480Rs in every melting of Ladle. Overall benefits in a year 12X15480= Rs Vedanta Limited, Aluminium - BALCO 19

21 GHG Inventorisation & Environment Management Initiatives Year 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 TOE (awarded 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 Vedanta Limited, Aluminium - BALCO 20 GHG emissions (Scope 1 + Scope 2) in MT CO2 eq. Metal Volume (MT) GHG emissions per Ton of Al Status of EnMS (ISO 50001:2011) Audit Observation IMS Year No. of NC No. of Observation Open NC Open Observation Balco Balco

22 Utilization of Renewable Energy 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 SNo. Area Start of Investment Payback End of Project Project ( In Lakhs ) (Years) 1 Comprehensive Building DM Plant Lab building 10 4 Canteen Plant HSE office - Plant Rectifier - Potline Rectifier - Potline Total 96 7 Vedanta Limited, Aluminium - BALCO 21 Status 28kwp system installed

23 Waste Management Usage of Emulsion after treatment Qty 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 TO WEALTH ) Vedanta Limited, Aluminium - BALCO 22

24 Green Supply Chain S.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 5 Use of GPS to identify shortest route 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 Ongoing Plans with Various Vendors Name of the Description of the Collaboration / energy reduction Sl. No. Vendor 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 Vedanta Limited, Aluminium - BALCO GJ/Month 200 GJ/Month PLANTATION DRIVE FY FY FY 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 Nos energy efficient light fittings and fans through Ujjala Scheme of EESL:-(May-16-June- 16) & (Jan-17 Apr-17)

25 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 24

26 Creating Awareness Among Stakeholders ENERGY QUIZ COMPETITION ENERGY QUIZ COMPETITION ICQCC WINNER -GOLD Place Thailand Bangkok Vedanta Limited, Aluminium - BALCO 25

27 Implementation of Best Practices Implementation of Idea generation portal 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 Title of Project Distribution of energy efficient light fittings and fans through Ujjala & Pawan Scheme in Balco township Name of the Vendor Per unit energy consumed Before Project After Project % Improvement EESL Kwh/day Kwh/day 5.55% Heater optimization at Himadri Chemicals Himadri % Vedanta Limited, Aluminium - BALCO 26

28 Awards and Accolades Vedanta Limited, Aluminium - BALCO 27

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