19th National Award for Excellence in Energy€¦ · Garmco(Middle East) Hindalco, etc Wire Rod Mill Technology • SOUTHWIRE, USA • Properzi, Italy. Plant Capacity • 120 KTPA

Aluminium Business1

19th National Award for Excellence in Energy Management – 2018

Asia’s 1st ISO-50001 certified Smelter

Team Members:

Bibhudatta Mohanty – Associate General ManagerManoj Senapati – Associate ManagerDilip Kumar Satpathy – Associate Manager

Aluminium Business2

Core Purpose “Vedanta is a globally diversified natural

resources company with low cost

operations. We empower our people to

drive excellence and innovation to create

value for our stakeholders. We

demonstrate world-class standards of

governance, safety, sustainability & social

responsibility”

PURPOSE & VALUES

Vedanta Core

Values

Trust

Entrepreneur-ship

Innovation

ExcellenceIntegrity

Respect

Care

Aluminium Business3

5 LTPA Aluminium Smelter 1215 MW CPP

12.5 LTPA Aluminium Smelter 2400 MW IPP

VEDANTA LIMITED, JHARSUGUDA

Aluminium Business4

MAKING OF ALUMINIUM

Aluminium Business5

❖ Pot Room:

➢ GP – 320 Prebake Technology

➢ No. of lines – 2

➢ No. of pots in each line – 304

➢ Pot amperage – 328 kA

➢ Design Capacity – 0.5 MTPA

❖ Carbon:

➢ GAP – 2 Paste plants

➢ Bake Oven – 4 Bake furnaces.

➢ Anode Rodding Plant

❖ Cast House

➢ Ingot Casting Mill – 3 Lines

➢ Wire Rod Mill – 2 Lines

➢ Billet Casting Line – 1 Line

SMELTER – 1

Conserve energy to preserve natural resources.

Aluminium Business6

Ingot Casting Machine

Technology• BEFASA, Spain

Plant Capacity• 450 KTPA

Product DestinationApar Industries Ltd. Jindal Aluminium Limited.STX, Daechang, Dreample (Korea)Southern Aluminum (China), etc

Slab Casting Machine

Technology• WAGSTAFF, USA


Product DestinationNovelis(Korea)Garmco(Middle East)Hindalco, etc

Wire Rod Mill

Technology• SOUTHWIRE, USA• Properzi, Italy.

Plant Capacity • 120 KTPA

Product DestinationPolycab Wires Pvt. Ltd.Havell's India LtdNepal Wires (Nepal)Etsec (Kenya), etc

Billet Casting Machine

Technology• WAGSTAFF, USA


Product DestinationCentury Extrusions LimitedAlom Extrusions Limited (Turkey)Hyundai Aluminum (Vietnam)Wespeco (South Africa), etc

PRODUCT MIX

Aluminium Business7

ALUMINIUM - ENERGY & COST

36%

64%

Energy Cost Other Cost

98%

2%

Electricity

Fuel

DC Energy

95%

Auxillary Energy5%

DC Energy consumption = 2.98*Volts/pot

Current Efficiency

Focus is on DC energy reduction

Conservation: It doesn't cost. It saves

Aluminium Business8

SPECIFIC ENERGY CONSUMPTION TRENDS

“Fruitful result of our efforts”

SPECIFIC AC CONSUMPTION (kWh/MT)

13939

13877

13862

1349313466

13400

13600

13800

14000

2015-16 2016-17 2017-18 Q1 2018-19 Target 2018-19

1370013643.25

13638

1329113258

12900

13000

13100

13200

13300

13400

13500

13600

13700

13800

2015-16 2016-17 2017-18 Q1 2018-19 Target

SPECIFIC DC ENERGY CONSUMPTION(KWH/MT)

SPECIFIC DC ENERGY

CONSUMPTION(KWH/MT)

SPECIFIC AC

CONSUMPTION(KWH/MT)

Aluminium Business9

PERFORMANCE BENCHMARKING

13817

1350013528

13405

13301

13000

13100

13200

13300

13400

13500

13600

13700

13800

13900

A B JSG-P2 JSG-P1 Balco

Kw

h/M

T

Indian Aluminium Companies

DC Power (Kwh/MT)

One measurement is worth a thousand expert opinions

Aluminium Business10

ENCON PROJECTS (Last 3 Yrs)

Zero investment projects

Investment Projects

“Small Investments, High Returns”

CategoryNo of ENCON

projectsEnergy Savings Energy Savings

Saving in Million Rs.(MkWh) (MKcal of fuel)

DC - - - -

Auxiliary 77 12.62 - 33.05

Fuel - - - -Total 77 12.62 - 33.05

Category

No of ENCON projects

Energy Savings (MkWh)

Energy SavingsSaving in Million Rs. Investment in

Million Rs.(MKcal of fuel)

DC 5 45.18 - 139.97 580.93

Auxiliary 21 2.16 - 6.97 14.14

Fuel 1 - 17062 61 15Total 27 47.34 17062 207.94 610.07


S.No. Title of Project

Annual energy

Saving,

Million kWh

Total Annual

Savings,

Million Rs

Investment

Made (Rs

million)

Payback

1 HP power optimization 4.99 12.53 0.00 0.00

2 Stoppage of bulk tank storage heaters in Bake Oven 0.24 0.59 0.00 0.00

3 FTA low vacuum unit run time optimisation 0.19 0.48 0.00 0.00

4 Lighting Energy optimisation in Rectifier 0.11 0.29 0.00 0.00

5Cooling Ramp shutdown Before fire change for 5

Hours0.11 0.26 0.00 0.00

6 Automation of cooling tower 0.09 0.22 0.00 0.00

7Running Hour optimisation of R Group Pumps in

GAP0.09 0.22 0.00 0.00

8 LP compressor tuning 0.09 0.22 0.00 0.00

9 Use of Cold sealing paste in pot relining 0.09 0.22 0.44 24.00

10 Timerbased valve in dryer 0.09 0.22 0.00 0.00

11 VFD installation in DRC id fan 0.08 0.21 0.25 15.00

12LCP room partition there by saving AC running time

and hence energy0.07 0.16 0.00 0.00

13Grouping system hydraulic power pack runtime

optimization0.06 0.16 0.00 0.00

14Decrement in Idle running of Hydraulic Pump in

Cast House0.06 0.16 0.00 0.00

15 Bypassing of filter pump motor 0.06 0.14 0.00 0.00

ENCON PROJECTS FY 2015-16

Total energy savings for FY 2015-16 = 6.9 Million Kwh




Annual Energy

Saving,

Million kWh

Total Annual

Savings,

Million Rs

Investment

Made (Rs

million)

Payback

1 Dead Pot reduction 13.84 35.99 12.60 4.00

2Improvement in rectifier conversion efficiency

by 0.04%2.31 6.01 0.00 0.00

3Reduction in Heater Tripping by DMAIC

methodology0.80 2.08 0.00 0.00

4 ETP power optimization 0.35 0.91 0.00 0.00

5 Sniff panel modification 0.15 0.38 0.00 0.00

6 CMW lighting load segregation 0.15 0.38 0.00 0.00

7 Rectifier unit LCP room AC optimization 0.14 0.36 0.00 0.00

8 Pump coating 0.12 0.32 0.00 0.00

9 Air slide fan running hour optimization 0.11 0.27 0.00 0.00

10 Auto Stop CWP5 after Billet casting cool down 0.10 0.27 0.00 0.00

11 New cooling tower running hour optimization 0.10 0.25 0.00 0.00

12Heating ramp heater temperature set point

optimization0.09 0.24 0.00 0.00

13 LED lights intallation 0.08 0.20 0.98 60.00

14 Eliminate Idle Running of F330 & F335 SC 0.06 0.16 0.00 0.00

15 Day tank heater Set point Optimization 0.06 0.15 0.00 0.00





Annual Energy

Saving,

Million kWh

Total Annual

Savings,

Million Rs

Investment

Made (Rs

million)

Payback

1 SGL100% cathode implementation 25.34 84.12 516.60 74.00

2 SHANDONG cathode implementation 5.91 19.61 51.28 31.00

3 FTP air slide fan optimization 0.65 2.15 0.00 0.00

4 VFD installation for new pump house 0.53 1.74 0.60 4.00

5 Pump coating 0.53 1.74 0.10 1.00

6

Replacement of existing lights with LED lights

in plant street light, office, MCC and shopfloor

areas

0.42 1.40 5.44 46.00

7 Cooling tower running optimizaion 0.26 0.87 0.00 0.00

8 Installation of energy efficient Air conditioner 0.11 0.37 3.47 113.00

9 Lighting Automation in different areas of plant 0.09 0.29 0.03 1.00

10CWP 4 Drive installation and to be run in 80%

capacity mode.0.09 0.29 0.31 13.00

11CT1 Drive installation and to be run in

temperature feedback control mode0.08 0.25 0.07 3.00

12Optimization of run time Grouping Hydraulic

motor by removal of lift shift operation0.07 0.22 0.00 0.00

13 Daytank heater set point optimisation . 0.06 0.20 0.00 0.00

14vacuum unit idle time reduce from 10 minutes

to 5 minutes.0.05 0.16 0.00 0.00

15 WCS cooling fan run time optimization 0.04 0.12 0.00 0.00



MAJOR ENERGY SAVING PROJECTS

(FY 2017-18)

Sl.No Project descriptionEnergy saving in MkWh/Annum

1 SGL100% cathode implementation 25.34

2 SHANDONG cathode implementation 5.91

3 FTP air slide fan optimization 0.65

Spare a Watt; Save a Lot


SGL100% CATHODE

Existing 50% graphitized cathodes are replaced with 100% graphitized cathodes.

Benefits of implementation:• Resistivity reduced from 26 ohm-cm to 12 ohm-cm.• Operating Voltage decrease from 4.182V to 4.126V• CVD (Cathode voltage drop) decreased to 247mV from 385mV• Which resulting a huge energy saving by the reduction of Specific DC energy consumption from

13369Kwh/Mt to 12874Kwh/Mt.

Energy saved is energy produced

Energy Conservation: 25.34 MkWh/ Annum

12400

12800

13200

13600

14000

92

93

94

95

96

30% Graphized Block 50% Graphized Block 100% Graphized Block

Kwh

/MT

%

Cathode Modification Journey

CE(%) DC Power (Kwh/MT)


FTP AIR SLIDE FAN OPTIMIZATION

Power saved is power produced

FTP is being operated with 2 airslide fans for conveying alumina in airslides. Airslide fan is being operated by a

55 KW motor which is running at 40% load for 24 hours a day. By switching off one air slide fan and operating

other at 60% load huge amount of energy is saved without disturbing environment by HF emission.

Energy Conservation: 0.65 MkWh/ Annum

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.40

0.45

1-Jun-17 8-Jun-17 15-Jun-17 22-Jun-17 29-Jun-17 6-Jul-17 13-Jul-17 20-Jul-17 27-Jul-17

FTP HF Emission Trend

FTP-2 Target


INNOVATIVE PROJECTS IMPLEMENTED

Before:

Volume of air consumed in

one cooling point = Volume

of air consumed in 1 inch

hose = 2.8 m3/min = 0.014

MW per day

After:

Volume of air consumed in

one cooling point = Volume of

air consumed in 1/4 inch

hose by nozzle = 0.22

m3/min = 0.001 MW per day

Nozzle & Cooling fin POT cooling

Energy saving = 13KW per day


Conversion of existing lights to LED

Energy Conservation: 0.42 MkWh

• For better illumination and energy saving, existing lights are replaced with LED in office, MCC room, Control

room, shop floor, street lights etc.

• Around 2000 nos. of existing lights of wattage (32W, 36W, 250W & 400W) were replaced with LED of lower

wattage(18W, 120W, 150W & 200W).

• 100% LED conversion by 2020.



VFD for new pump house

2 no's of 110 KW VFDs are installed in

two pumps, we observe energy saving

30kW/pump.


Around 70 no’s of split AC replaced with

energy efficient Air conditioner in

different location of Plant.


Energy Efficient Air conditioner



VFD installation in Cast house cooling tower-1

Repaired Drive installed in cast house cooling tower-1

which leads to save energy upto 8KW per day.

Temperature RTD installation in cold well sink to get

the temperature feedback of cold well. Based on the

closed loop feed back the CT runs



Aluminium Business21 It’s Your World. Take Control

10KW SOLAR SYSTEM


SOLAR WATER EVAPORATOR

Energy Saving 5000 Units/Annum

Planning of commissioning around 200KW solar power system in the near future.

RENEWABLE ENERGY SOURCES


Sl No. Initiatives Taken

1 Co-Incineration of Contaminated Carbon Dust and Anode Butts in CPP

2 Incineration of used Bag Filters in Baking Furnaces

3 Regulated consumption of Contaminated Alumina

4 Recycling of waste of Ramming Paste in Carbon Plant

5 Recycling of broken Cathodes in Carbon Plant

6 Recycling of Refractory Waste

7 Recycling of used steel stub pins in cast iron

8 Recycling of used steel collector bars

9 Recycling of effluent water for gardening

10 Rejected Anode butt utilization

UTILISATION OF WASTE

“Whatever Half Full or Half Empty, Resources are limited”


Efforts towards GHG emission reduction :

▪ GHG calculation done by M/s KPMG.

▪ Shuttle service started to optimize light vehicle movement.

▪ 100% Alumina transportation through rail traffic.

▪ 100% Finished goods transportation by rake.

CARBON FOOT PRINT ACTIVITIES

Let's Cut Carbs...Our Carbon footprint, that is

YearScope 1 emissions

CO2e (MT)Scope 2 emissions

CO2e (MT)Scope 3 emissions

CO2e (MT)CO2e MT

MitigationTotal Reduction in emission intensity since baseline year study CO2e (MT)

2014 - 15 8673537 1,697 323,278 8,998,512 Baseline Year

2015 - 16 10568356 8,403 321,478 10,897,237 -1,898,725

2016- 17 15098803 45,942 399,815 15,544,560 -6,546,048

2017- 18 19827752 76,404 738,042 20,642,198 -11,643,686



Reduction in specific HFO consumption

43.5

44

44.5

45

45.5

46

46.5

47

47.5

FY' 16-17 FY'17-18 FY' 18-19 (Target)

47.13

46.08

44.98

Improvement Actions Taken:➢ Optimization of pulsing oil injection in heating ramp. i.e, Firing of oil started after 8 hours of fire changeover maintaining CRR of

92%.➢ Peep hole modification done by putting ceramic coating cloth in it by reducing top surface temperature from 346 degree Celsius to

185 degree Celsius.➢ Gap between burner stand & ring is covered with packing coke.

Way forward:➢ Firing system level-2 SCADA up gradation for monitoring of flooding index of HFO and CO2.➢ Provision of flow meter in each ramp for better monitoring of HFO consumption.

Gap between burner stand & ring

Gap covered with packing coke

No covering around burner base

Covered with coke around burner base



Reduction in Specific Diesel consumption

2.7

2.72

2.74

2.76

2.78

2.8

2.82

2.84

2.86

FY'16-17 FY'17-18 FY'18-19(Target)

2.85

2.81

2.72

Improvement Actions Taken:➢ To optimize the idle running of engines in full RPM at the time of seal changing and pressure making in workshop, external compressor

unit installed to perform the pneumatic related operations in metal tapping vehicles.➢ Shortest path identification for process vehicles movement in plant premises.

Way forward:➢ Software up gradation in 2 MTVs by changing the controller and related programming so as to get the fuel savings like MTV 15



Reprocessing of Spent Pot Lining (SPL)

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

2015-16 2016-17 2017-18

684.24 1003.54

9005.5

Quantity of SPL(MT)

Way forward :

Tie-up with Green Energy Reprocessor for evacuating 4,200 MT per month with a vision of evacuating

entire SPL from our site in a time span of 18 months.


E-DMS DOCUMENT CONTROL & APPROVAL

ENERGY EFFICIENT PROCUREMENT

DIGITISATION OF EnMS

E-CER (CAPEX PROJECT) ENERGY IMPACT ASSESSMENT

MES ONLINE FLASH REPORT

“Automation leads to Perfection”


ENERGY MONITORING & REPORTS

SEC Report to Plant Head

Section Wise Report to Energy Managers

Daily reports to HODs

Energy Management SCADA

Parameters & Monitoring Frequency

High Energy Consumers Daily

Fuel Consumption Daily

Compressed Air Consumption Daily

Water Consumption Daily

“Monitor to Control”


Non-Conformity Statement :

➢ In significant activity sheet maintenancerelated activities which impact to theenergy performance was notmentioned.

Corrective Actions Done :

➢ Significant activity sheet prepared forthose maintenance activity which isimpacting energy consumption.

IMPLEMENTATION OF CORRECTIVE /

PREVENTIVE ACTIONS


Flow measurement

Major Energy Consumers

• Integrated Energy Meters are installed in the Sub Stations

• Related Process parameter are displayed on the screen

• Data is captured from these resources at regular intervals

Other Energy Consumers

• Energy consumption is measured by Power Analyzers before & after the Project for quantification of savings

• Flow measurements are taken for quantification of savings before & after the project

• Fuel consumptions are validated by third party auditors every month

• Meters used for all measurements are calibrated as per ISO Standards

“Well defined measurement system to quantify & validate ”

Energy measurement

Integrated Energy Meters

Flow measurement

ENERGY MONITORING & QUANTIFICATION


ENERGY CONSERVATION WITH TQM

“Improvement is an Infection”

2016-17 NOS.

SAVING

INVESTMENT (Rs. In Million)

NOS. OF PEOPLE INVOVEDPOWER

(Million Units/Annum)COST

(Rs.in Million)

SIX SIGMA 1 0.65 2.15 0 12

QC 2 0.64 2.11 4.07 10

KAIZEN 17 2.85 5.62 7.955 to 6 members in each

project

Conserve to Preserve


PEOPLE INVOLVEMENT

Energy Dash board on Shop floorEnergy discussion in daily War-room

Energy awareness in Tool Box Talk.Awards & Recognition for Energy

initiatives

“We value every small contribution”


ENERGY CONSERVATION WEEK

Cherish the earth through energy conservation.


Energy Policy

Energy Review

EnPI

&

Sub- EnPI

Opportunity List

Objective, Targets &

Action Plan

Monitoring, Measurement

Analysis & Review

Energy Audit , Corrective &

Preventive action

ENERGY MANAGEMENT SYSTEM

(ISO-50001)

1st Smelter in Asia ISO-50001 certified


REVIEW STRUCTURE

Formation of Energy Cell

SBU level energy review

Review by Energy Manager

Management review by Plant

Head

Monthly operation review

by Head Aluminium operations

Corporate Sustainability

review

APEX Committee

CORE Committee

COORDINATING

CommitteeSGA Team

“Bottom to Top Approach”


ENERGY POLICY & OBJECTIVES(2018-2019)

ENMS OBJECTIVES

▪ Reduce DC Energy Consumption▪ Reduce Auxiliary Energy Consumption ▪ Reduce HFO Consumption ▪ Reduce Diesel Consumption


Air Pollution Management

• De-dusting units along with bag filters

• Introduction of Electro Static Precipitator (ESP)

• Installation of CAAQMS for continuous air quality monitoring

Water Pollution

Management

• Online waste water monitoring system

• Storm water guard pond

UF & RO PlantReal time monitoring of ambient air

ENVIRONMENTAL PROJECTS & INITIATIVES

Every action has a reaction


Waste Management

• Segregation biodegradable & non biodegradablewaste

• High Concentration Slurry Disposal (HCSD) -1st In Odisha

Hazardous Waste

Management

• Secured Landfill

• Use Of Incinerator (Fluorinated Waste)

Hazardous Waste Incinerator

Hazardous Waste LandfillHigh Concentration Slurry Disposal


Earth: Cherish or perish.

Biomedical Deep burial pit

Color coding for diff. types of waste


Water Conservation▪ Treatment and recycling of effluent water▪Principle of “Zero” effluent water discharge▪Upgrading ETP with Ultra-filtration & Reverse Osmosis for maximum water recycling.▪Storm water guard pond for management of storm water.▪Installation of robust quality of float vales to avoid overflow of water from sintex tank.▪Recycling of Ash pond water for using in ash handling plant

Rain Water Harvesting• A study on Rain Water Harvesting has been

conducted by Andhra University and the report has been submitted to CGWA / OSPCB for their technical suggestion.

• Approval received from CGWA.


“Every drop counts”


“Each one Plant one” taken on world Environment Day in which all employees & contractors have planted one tree across the location

Environment Incident Management System

Waste Management Systems under Sustainability Framework

Rehabilitation of Ash filled area by plantation

Green Jharsuguda Project – in PPP mode 100750 saplings at Behrapat, Lohrabudh & Banjari village

INITIATIVES FOR A GREENER TOMORROW

“Fulfilling our dream of Clean & Green India”


ENCON EFFORTS –A NOTCH UP

Energy Audit by CII

Energy Audit by TERI

EnMS Implemented

ISO 50001 Certified ENCON award from BEE and CII

ENCON award from BEE , CII & GMEA

Russian Gov. Award-Best Energy Efficient project realized abroad

FICCI audit, M&V audit-PAT

NECA -2nd Prize

Energy Management Insight award

PAT cycle-1 best achiever award SEEM award

2010

2011

2014

2012

2015

2013

2016

2017

Clamp Drop

Fuse Technology

Slotted Anode

Cathode &

HFO

HFO & Conversion Efficiency

Technology up gradation in potline


ENCON PROJECTS

(Ongoing/Upcoming)

“Our plans for a better Tomorrow”

Sl.no Title of Project YearEstimated Annual

Savings, MkWh

1 Revamping of homogenising furnace and up gradation of insulation 2018-19 3.577

2Pot controller and lining design up gradation to improve specific DC

energy consumption2018-19 324

3 VFD installation for pumps and fans 2018-19 15.4

4 Energy efficient coating on pumps 2018-19 0.29

5Interconnection hot water line with make up water line to switch off

filter feed pump in casthouse2018-19 0.482

6Current efficiency improvement in pots to reduce specific DC energy

consumption2018-19 101

7 Use of graphite particle instead of resistor coke 2018-19 1.65


Adoption of New technology of Cell lining

Up-gradation of Pot Control & Feeding System

ROAD MAP TOWARDS BENCHMARK

MV drive for FTP ID Fan

HFO SCADA level-2 upgradation

“Measure to Control, Benchmark to Better”


AWARDS & RECOGNITIONS

Recognition is the greatest motivator

✓ Recognized as “Energy Efficient Unit” at 18th

National Award for “Excellence in Energy Management” organized by CII.

✓ Silver award for best energy management from SEEM.

✓ PAT cycle-1 best achiever award from BEE.


It takes

To transform

One will

A million life

We harness our Collective will

Energy ConservationA Way of Life

To make

At Vedanta Jharsuguda

Thank You

Documents

19th National Award for Excellence in Energy€¦ · Garmco(Middle East) Hindalco, etc Wire Rod Mill Technology • SOUTHWIRE, USA • Properzi, Italy. Plant Capacity • 120 KTPA