2nd Sector Learning Group (SLG) meet for Aluminium sector & Second Workshop on Best Practices in Energy Efficiency in Aluminium Sector CAPTIVE POWER PLANT, VEDANTA ALUMINIUM LIMITED, JHARSUGUDA
2 PLANT PROCESS
KEY HIGHLIGHTS HSE We are maintaining zero LTI & MTI since 649 days. YTD figure for Ash utilization is 67.59%. We have implemented sequential LOTO & personalized LOTO.. We are conducting safety campaign in every week at our site for awareness of down level people. Certification Certified for IMS(ISO 9001,14001,OHSAS 18001). Certified for EnMS (ISO 50001). Certified for Asset Management System (ISO 55001). Certified for 5S by QCFI. And sustaining the Par Excellence status from 2015 to till date. 3 3
BUSINESS EXCELLENCE 5S 5S has laid Business Excellence Foundation with structure of 6 zones and 24 Subzones is continuing. CPP achieved Par Excellence award for 5S performance and best presentation in National 5S conclave. QC QC teams are operational Including direct & indirect employees with 80% coverage for both. CPP received gold award and nominated for NCQC in FY 2016-17. Six Sigma Wave-5 drive has started with 4 top priority projects covering 105 employees. CPP team received gold award in CCQC in FY 2016-17. Kaizen Completed 72 Kaizen projects in last 6 months. CPP received gold award in CCQC and Par Excellence in NCQC in FY 2015-16. CPP received gold award and nominated for NCQC-2016 & one team received silver award in CCQC in FY 2016-17. 4
ENVIRONMENTAL PROJECTS Improvement of Fly ash Utilization 1.Ash utilization was 20%. 2.5 Brick companies are associated. 3.Less Ash is utilized for road. 1.Ash utilization is 67.59% 2.95 Brick companies are Associated. 3.150 NH Development for we are supplying ash of 4000tonne/month 4.Development of village road of 3 km from Banjari to Sarbahal with 15000tonne of ash. ESP Bag Filter Retrofitting. 1.Designed ESP had 5 fields 2.Ammonia dozing was in process 3.Avg. SPM was more than 100 mg/nm3. 1.Last 2 fields replaced with Bag filter 2.Ammonia dozing stopped 3.Existing Ash Conveying system is modified 4.Avg. SPM < 30mg/Nm 3 5
IT ENABLEMENT E-DMS Document Control & Approval E-Test for EnMS Energy Efficient Procurement E-CER (Capex Project) Energy Impact Assessment 6
REDUCTION IN SEC 10.60% 10.20% 9.80% 9.82% 10.14% Auxiliary Consumption 10.24% 9.84% 9.63% 9.66% 9.58% Design : 9.00% Benchmarking : 9.00% 9.40% 9.10% 9.00% 8.60% 8.20% 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 BP 16-17 Units in Commissioni ng Stage a) Installation of Additional Compressors b) Installation of New ID fans c) Truck Tripler Commissioning d) Ultra filtration Commissioning a) BFP recirculation valve replacement b) CT Fans Blades Replacements c) Installation of VFD s d) CW Interconnection e) Installation of Natural roof Ventilation Fans f) Optimization of Compressor Running Hrs g) Replacement of Existing Dryers with Energy efficient dryers 7
REDUCTION IN SEC 920 900 880 860 840 820 800 780 760 740 720 910 893 Specific Coal Consumption 821 814 806 814 807 Unit : Gms/Kwh Design : 789 Benchmarking : 795 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 BP 16-17 795 Units in Commissioning Stage a) Commissioning of Ultra filtration b) Turbine Overhauling c) Replacements of Turbine Drain Valves d) Operational Improvements a) Replacement of CT fills b) HFO to LDO gun conversion. c) Additional cooling tower cell. d) APH O/H, Soft Touch Seals Installation & Basket replacement. e) Turbine Seal Checking & Rectification f) Condenser Cleaning g) Operational Improvements 8
REDUCTION IN SEC 3.5 3.67 Specific Oil Consumption Benchmarking : 0.05ml/kwh 3 2.5 2 1.5 1 0.5 0 0.8 0.21 0.09 0.09 0.11 0.08 0.05 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 BP 16-17 Units in Commissioning Stage a) Reduction of Forced Outages b) Availability of Mills and Feeders c) Installation of Air Blasters d) Reduction in Bunker Choking a) Optimization of Cold Startup b) Availability of Critical Equipment c) Improved Operational Controls 9
Project: IMPROVEMENT PROJECT Isolation of SWAS grab Sample. Thermal saving is 3692.16 Tonne/Year & electrical saving is 0.1270MU/Year which is 0.9 million /year. Before: The flow of sample is continuously draining, when the sample was collected only twice in a shift. After: The flow of the sample was adjusted from the PRV & manual sample line is isolated and parameter was observed and found normal. Before After 11
IMPROVEMENT PROJECT Condenser Cleaning (Jet, bullet & chemical): Condenser Jet cleaning=1 unit; Bullet cleaning=4 Units; Chemical cleaning=1 unit Average improvement of 20 kcal/kwh/unit/kpa in Heat Rate. Annual saving- Rs. 41.55 Millions BEFORE AFTER 12 12
IMPROVEMENT PROJECT Installation of Refrigerant drier: A Energy efficient, eco- friendly drier Previously desiccant drier was installed which was consuming 38KW /hour. We have replaced it with Refrigerant Drier which is consuming 11KW/Hour. Also we are using environment friendly R22 gas. Before After 13
IMPROVEMENT PROJECT CW Interconnection As per design, we need to run 2 cooling water pumps to get required condenser vacuum. But at the time of season transition we need 1.5 CW pump and we have to run two CW pump due to design constraint. we have done cooling water pipeline interconnection by joining inlet pipelines to two adjacent units. The said modification allows us to stop one pump with a saving of 900 kw for four month(transition period of seasons). 14
HFO to LDO Conversion IMPROVEMENT PROJECT Reduction Of Steam consumption (Purging Steam) by converting HFO to LDO. Steam Saving:12303 T/year Cost Saving :1.91 Crore/year 15
CT Fans Blades Replacement For each unit, 5 CT cells : are designed for maintaining desired parameters. The weight of GRP blades is more than FRP blades. Total 40 out of 45 nos. of GRP blades replaced with FRP blades. Average Power Saving is 21Kw/Fan. Total Saving: Rs. 17.2 Million. IMPROVEMENT PROJECT Before After 16
Replacement of Old Chrome rollers with New Sinter Cast Rollers & Liners Rollers & Liners are replaced by New Sinter Cast Rollers Reduction in Mill power consumption by 30 KW. Running hours increased from 6000 to 20000 hrs. Improvement in mill outlet coal fineness. IMPROVEMENT PROJECT Before After 17
IMPROVEMENT PROJECT Replacement of Air Preheater Baskets & Addition of Soft Touch Seals : Air Preheater Baskets and soft touch seals were replaced resulting in improvement of boiler efficiency by 0.5 %. There is Reduction in Primary Air fan (PA) loading of 103 Kwh due to less leakage because of soft touch radial seals. Total Saving: Rs. 78.15 Million. Before After Average energy Savings : 100 Kw/Unit 18
PROCESS IMPROVEMENT Online cleaning & replacement of New CT Fills Replacement of CT fills has been done with new design incorporating following improvements. Flute size change from 17 mm to 19mm to avoid choking in rain zone. Increase in total height from 1675mm to 1800mm to increase surface area. Total height is split in 4 layers for ease of handling and maintenance. This leads to vacuum improvement of 1 kpa with a saving of 22 lacs /Unit/month. Before After Average Savings : 1 Kpa /station 19
PROCESS IMPROVEMENT Replacement of BFP recirculation valve and seal ring Refurbishment of BFP recirculation valve internals. Replacement of existing recirculation valve with improved design(4 stage). Saving of 100 Kw/pump Annual Saving: Rs. 16.3 Million Before After 20
CW pump Impeller coating: CW pump impellers coated with Brush able coating Reduction in CW pump loading by 68 kw Improvement in CW flow Saving of 10 kw/pump Annual Saving: Rs. 12.14 Million. IMPROVEMENT PROJECT 21 21
IMPROVEMENT PROJECT Reduction of speed through winding Modification of CW: Motor for Pole Changing(16 to 18) which can give the design flow data of CW Pump 71496 m³/hr Power saving up to 1 MW to reduce the flow of cooling water pump. 1.2 MW per hour Total 864*4 Total units 864 mw/unit/month 3456 mw/month 34560000 Kwh 22 5
USE IGNITE OIL INSTEAD OF LDO OVER VIEW Saving Potential based on last year consumption (H2 & H1 - FY'15) 1. In order to reduce the oil cost we use the alternate fuel oil i.e. Ignite Oil. Ignite oil is prepared from Blending/ Mixing of 2. Its quality is similar to the Light diesel oil. CATEGORY JSG KL 1,155 Saving (Rs./MT) 9026 Saving (Mn $) 0.16 Total Savings (Million $) 0.75 COMPARISION: Material(Rs./KL) SOURCES Comparison Sheet basis LDO IOCL - Vizag LDO IOCL - Budge Budge Fortis Light (Alternate Fuel) Fortis - Jharsuguda Ignite Oil (Alternate Fuel) Thirubala - Khurda Basic Price 30824 36718 34670 28500 Tax/Discount 8754 5836 1205 2041 Net landed cost payable 39567 42554 35875 30541 Savings in Rs/KL 3,692 9,026 Savings % 9.3% 22.8% 23 1
TURBINE WASHING RESULTS HPT First Stage Pressure 130 Saturated steam washing has resulted in encouraging improvements in HP turbine parameters. First stage pressure and extraction 1 pressure have improved by 10 Ksc & 8 Ksc. 125 120 124 125 126 122 126 There were slight improvements in stage pressure resulting from improvement in heat rate and less flow requirement for same load. 115 114 115 114 116 115 115 114 It also indicates that there was not considerable deposit on IP & LP turbine. 110 BENEFITES Turbine Heat Rate improved by 65 Kcal/KWhr Total Coal saving in a year: 86477MT Unit load revive to 600MW,which was restricted to 550MW 24 1
ENERGY REPORTING & QUANTIFICATION Monitoring system Integrated Energy Meters are installed for HT & LT motors and configured in DCS. Meters used for all measurements are calibrated as per ISO Standards Related Process parameter are displayed on the DCS screen. All relevant energy data is captured from these resources at regular intervals by PDHR data. Installation of MES system. 25
BEST PERFORMANCE MONITORING PRACTICES Monitoring system CT fills DP & Air Flow measurement APH Air ingress / leakage test Condenser air ingress / Drop test Online CT fills cleaning Clean Air velocity test (Mill orifice adj.) High energy Drain temp 26
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