Alumina Technology

8/12/2019 Alumina Technology

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ALUMINA PLANT REFINERY PROCESS

Introduction:

Bauxite is the raw material from which alumina is extracted by alkali

process. Invented by Austrian Scientist Karl.Josheph Bayer, in nineteenth

century, it is the only process available for commercial extraction of

Alumina hydrate. he bauxite is mixed with hot sodium hydroxide solution

to dissolve alumina present in it. !sin" various techni#ues such as cyclonic

separation, settlin", and filtration separates the non$reactive part consistin"

mostly iron oxide. he soda solution havin" dissolved alumina in it is then

precipitated out at low temperature to "et alumina hydrate as intermediate

product. his is calcined at about %&&&'( to "et alumina.

Bauxite excavation capacity) *+lakh tonesyear

Alumina production capacity) -lines /.0/lakhtonsyear1%/.2/lakh

tonesyear

BAUXITE

he ore for alumina is present in different form and composition. he

tropical bauxite present in the hills of 3anchapatmali of 4aman5odi has

followin" components.

6 Al0'-,-70' 8IBBSI9

6 Al0'-, 70' B'79:I9

6 ;e0'- 79:AI9

6 Al0'-,0Si'0,I?I9

6 Si'0 @!AI9

6 70' ;99 :'IS!9

6 C0'/ CA?A4I!: 39?'DI49

6 i'0 IA?I!: 4I'DI49

6 8a0'- 8A>I!: 'DI49

he components are expressed in more useful terms and approximate

composition is as follows

6 Al0'- */E

6 ;e0'- 0/E

6 Si'0F %.2 E

6 Si'0 0.- E

6 >'I 0-E6 i'0 0E

6 C0'/ %E

6 30'/ A(9S


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6 8a0'- A(9S

At minin" site, after removin" the overburden, holes are drilled and

trinitrotoluene is used as explosive for breakin" the deposit. hen rock$

breakin" machines are used to reduce the siGe of ore to below +&&mm. he

material is then transported by dumpers to crusher house and crushed to

below %/&mm siGe by two numbers of toothed double roll crushers also

called as primary crusher. he crushed bauxite is then transported to alumina

plant by a special conveyor called as cable belt. he specialty of cable belt is

that it not only has vertical curves like conventional belt conveyors but also

has several horiGontal turnin"s to meet the re#uirement of hilly terrain. he

sin"le fli"ht %*.Hkm lon" conveyor is supported on a rope, which is driven

by a synchronous motor.

At alumina plant, the bauxite is stored in open yard stack piles and

reclaimed at specified rate by two numbers of bucket wheel reclaimers. he

material is then crushed by three numbers of hammer crushers to siGe below

-&mm and stored in stora"e tanks called as silo.

BALL MILL

Because the process of alumina processin" involves solid bauxite and li#uid

sodium hydroxide reaction, fine siGe of solid is necessary to have better

reaction and hi"her yield. he bauxite from silo is extracted at measured rate

and fed to ball mill, which "rinds the material to about H-micron siGe. he

"rindin" process is accelerated by addition of dilute caustic soda solution at

%/&"mlit soda concentration. 9ach of the four ball mills has "rindin"

capacity of 0&&tonshr. 9ach ball mill is loaded with about %&&tons of hyper$

steel spherical balls and rotates at %/3:. hree streams of the plant

operate with four ball mills. he "round bauxite in caustic soda solution is

called as mill slurry is pumped to subse#uent process called as pre$

desilication.

IMPORTANT TERMS

Soda concentration) expressed in "rams of soda present in the li#uor in the

form of sodium hydroxide and sodium meta aluminate and expressed as

?a0'.

RP) this is the ratio between alumina present in sodium :eta aluminate

form, expressed as Al0'- and the soda present in the form of sodium

hydroxide sodium :eta aluminate expressed as ?a0'.

Al0'-, -70') alumina tri$hydrateAl0'-) Alumina or calcined alumina


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PRE-ESILICATION

he silica present in bauxite in the form of kaolinite is called as reactive

silica, since it reacts with sodium hydroxide easily to form sodium silicate.

his sodium silicate deposits as scale on the wall of the vessels and heat

exchan"ers resultin" in reduced process efficiency. hats why pre$

desilication process is desi"ned to convert harmful reactive silica to non$

reactive sodium aluminium silicate. he mill slurry is heated with steam to

react kaolinite with sodium hydroxide to form sodium silicate. After that, the

slurry is passed in tanks where sodium silicate is converted to sodium

aluminium silicate or sodalite. Sodalite is a hi"hly stable compound and not

reactive with sodium hydroxide any more.

Al0,0Si'0,


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separated from bottom. he slurry havin" very small particles come out

from top of the cyclone and come to a tank called as dilution tank. he

separated sand is washed with water to extract soda from it and the washed

li#uor is fed to dilution tank. he slurry here also contain solid and separated

in subse#uent sta"es and washed with water for soda recovery. he wash

li#uor derived from there is partly mixed in dilution tank to "et desired soda

concentration of %H2"mlit.4iluted slurry has about H&"mlit of solid and at

%&0'(. 4iluted slurry is pumped to post desilication tanks.

POST ESILICATION

emainin" amount of reactive silica, which could not react with soda in

3redesilication, reacts in di"estion and forms sodium silicate. his sodium

silicate has to be converted to non$reactive sodalite in precipitation. ;or this

purpose, diluted slurry is heated in post desilication tanks up to %&/'( and

retained for about +hrs.the slurry is slowly a"itated in post desilication tanks

to 5ust avoid settlin" and facilitate sodalite formation. ;avorable condition is

hi"h temperature and low concentration. 'utlet of this process is pumped to

settler for solid waste separation.

SETTLER

hese are bi" tanks havin" diameter of *&m and hei"ht Hm. 4esilicated

slurry is fed at the centre and the mud settles down and clear li#uor remains

at the top. Slow speed rake mechanism drives the settled mud from centre to

periphery. Synthetic flocculant is dosed to the settler feed to enhance rate of

settlin". Settler overflow containin" about *&&m"lit of solid and %H/"mlit

soda is collected in an overflow tank. he underflow of settler containin"

/&&"mlit of settled mud is washed in six sta"es with water to recover

maximum amount of soda. 3art of that wash li#uor is mixed with settler

overflow li#uor to attain %*+"mlit of soda concentration i.e. favorablecondition for alumina precipitation. he li#uor thus achieved is pumped to

security filter feed tanks for third and last sta"e of solid impurity removal.

SECURITY FILTRATION

Since *&&m"lit of solid impurity in the li#uor will make the alumina impure

in precipitation up to unacceptable limit, further separation of solid is done

by means of filtration. ;or this purpose, settler overflow li#uor is filtered insecurity filter or Kelly filter to brin" down the solid from *&&m"lit to below

-&m"lit. Kelly filters are pressure leaf filters bein" operated at -ata

pressure. @uick lime solution is used as filter aid to help in filtration. he


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li#uor there after is called as aluminate li#uor and is ready for of alumina

production by precipitation. he soda concentration here remains at %*2"pl,

3 at %.&H.

PRECIPITATION

Aluminate li#uor is cooled down to about H/'( in plate heat exchan"ers to

achieve better precipitation. As per #uality demand of precipitated products

"rain siGe is most si"nificant and in order to achieve bi""er particles, small

hydrate particles are mixed with aluminate li#uor so that alumina hydrate

precipitation takes place on those particles and their siGe increases. At the

end of precipitation process, the particles are classified as per siGe and

coarse particles are taken out as final product hydrated alumina. he fine

particles are mixed with fresh aluminate li#uor to allow precipitation on the

surface to make them "row further. In this manner the coarse products are

taken out and fines are recycled to precipitator after mixin" with aluminate

li#uor. After classification of the precipitated products, slurry containin"

coarse particles is filtered in product filter to remove the mother li#uor

called spent li#uor. he fine particles slurry is filtered in seed filters to

separate the mother li#uor called as spent li#uor. he spent li#uor received

from both product and seed filters is heated up in plate heat exchan"ers

while coolin" aluminate li#uor and dispatched to evaporation area.

he seed hydrate is not only put in aluminate li#uor for particle "rowth but

also for increasin" the rate of precipitation as auto precipitation rate of

aluminate li#uor is very low. >ow concentration of soda in aluminate li#uor,

low precipitation temperature, hi"h surface area of seed hydrate, hi"h

amount of seed hydrate are favorin" factors for better precipitation.

Aluminate li#uor mixed with seed is kept in precipitators for about *&hrs to

achieve substantial production. here are %H precipitators of *0&&m-

effective volume each in each stream. he precipitators are also cooled inbetween to decrease the temperature to "et more yields.

he spent li#uor at concentration of %/&"pl soda is pumped to evaporation

area and product hydrate proceeds to calcinations area.

E"APORATION

he spent li#uor at +&'( is stored in spent li#uor tanks. 3art of the li#uor ispumped to ball mill to help in wet "rindin" and 3redesilication. :a5or

portion of the li#uor is concentrated in evaporators and used for di"estion.


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here are six evaporator batteries, each have six effects. Any one of the first

five effects can be bypassed for maintenance purpose. hese are fallin" film,

backward feed evaporators. Steam is used for heatin" the spent li#uor and

boil to "et vapor, so that the li#uor "ets concentrated.

e#uired evaporation ) +&&tonshr of water

Steam used ) 0H&tonshr

he steam condensate from these multiple effect evaporators is sent back to

steam plant. 8enerated vapor is condensed in different effect and the

condensate is used in different area as sodic condensate. o enhance

capacity of evaporation battery, last effect is operated under vacuum and

sprayin" coolin" water to the "enerated vapor "enerates the vacuum. he

product of evaporation battery is called as "reen li#uor as it is capable of

"ivin" productionM the temperature is %&/'( and concentration is 00/"pl.

CALCINATION

he hydrated alumina received from precipitation is washed in drum filters

to reduce impre"nated soda. In order to remove bound or chemically

combined moisture i.e. -70' from the hydrate it is sub5ected to temperature

of %&&&'( furnace. he temperature is achieved by burnin" fuel oil with air.

here are three fluid bed calciners which have rated capacity of //&& tons

alumina day.

he alumina is transported to silos by belt conveyors and from there by

railway wa"ons to An"ul and CiGa".

#UALITY OF ALUMINA

6 37NSI(A> @!A>IN

6 $*/ %0Emax

6 %0/ %/Emax

6 B9 Area H&$+&:08:

6 >oss on i"nition %E:AD

6 content %&E:AD

6 (79:II(A> 3'39N6 Al0'-


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6 ?a0' &./E:AD

6 (a' &.&/E:AD

6 Si'0 &.&0E:AD

6 ;e0'- &.&%/E:AD

SPECIFIC CONSUMPTION OF RA$ MATERIALS

6 BA!DI9 0.H/'? 'I> +&K8

6 >I:9 *&K8

6 (N9( -&&8:

6 BA? *K8

6 (8: %K8

6 OA9 *'?S

U%e o& a'u(ina:

%. :ainly for manufacture of aluminium

0. In ceramic industries for manufacture of refractory

-. ;or manufacture of tooth powder, tooth paste

STEAM AN PO$ER PLANT

?alco is a purpose utility. he main purpose is the production of

Alumina from bauxite. In this process of conversion of bauxite into

Alumina, steam is a ma5or prere#uisite, which is used in various unit

operations.he unit operations where steam is re#uired are as follows)

4i"estion

3redesilication

4esilication

(lassification

9vaporation

(alcinations ;locculation

Keepin" in view the re#uirements of steam in the process of the plant,

durin" the time of installation a boiler was set up which would boil water


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usin" oil and coal to heat water to steam. But with time it was seen that the

plant could produce more steam then was re#uired i.e. only a part of it was

utiliGed. It was only then proposed to use this steam in power "eneration in

addition to its utiliGation in unit processes. his led to establishment of a

steam a power plant unit (' 4aman5odi. S33 is called a

co"eneration plant because it helps in the production of both steam and

power. his steam is "enerated from the boiler and the power is "enerated

usin" this steam in a turbo "enerator. A turbine and a "enerator set up are

used for the production of power usin" steam.

here are various units, which are included under the steam and power

plant at ?A>(' 4aman5odi. All these units are interconnected and affect

each others performance. he units are as listed below

4: 3lant

;uel 'il 7andlin" plant

(oal 7andlin" 3lant

Boiler

urbo "enerator

Ash 7andlin" 3lant

All the units were studied in the above order every section has an

intricate use of pro"rammable lo"ic control system (= makin" thewhole plant an automated unit. ?alco is further focusin" on convertin"

this whole 3>( system to a 4istributed (ontrol System


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of >4' tank is 0/m3.All the three tanks have an earth "rid resistance of

&.%2H ohm.

here are specialiGed suction pups for drawin" oil from 7;' and >4'

tanks there are three >4' suction pumps and three separate 7;' pumps.

hese pumps are used dependin" on the re#uirement in the boilers. If the

re#uirement is less one of the pumps is used as a standby. hese pumps

pump oil from the tank and direct it towards the strainer. hese strainers are

two in number and they are aimed at filtration of the oil in order to remove

the oil sediments. he filtered oil from the strainer is sent to the oil heater.

hese are also two in number, one standby and one inline. his oil heater is

used to reduce the viscosity of oil so as to make the oil suitable for boiler

operation. his oil is heated by interactin" it with steam at a pressure of %%

ata and temperature of 00& de"ree (elsius

his oil is channeliGed into the oil "uns where it is used for li"htin" up

the boiler.

;uel oil >i"ht density

oil4'=

7eavy fuel oil

Standard ISI *H&%L2* ISI %/L-%L2%

3our point


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coal used in the boiler is known as B$ "rade coal, i.e. bituminous variety of

coal. he coal is now made to under"o a series of processes before bein" fed

to the boiler. he processed coal is sent to the coal handlin" plant. And then

it is used up by the coal feedin" plant.

Coa' un'oadin2 %0%te(: -the coal from wa"ons is fed to a hopper by

means of a rotaside wa"on tippler. he coal from hopper is fed to the

vibratin" feeder. By means of vibratin" action it is made to pass into the

techno chute by means of a conveyor and flap "ate arran"ement. his coal is

stocked in the techno chute.

Coa' &eedin2 %0%te(: - this system has been so desi"ned to separate

the iron components in the coal stock. his is done because iron presence

hinders steam formation. A (B: is installed for this purpose


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Ash produced due to combustion in the boiler needs to be disposed off

safely so that it does not have an adverse effect on the environment or the

people.

his function is carried out by the ash handlin" plant. 'ut of the total

ash produced 0& Eis known as bottom ash which is collected in the water

impounded furnace


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An 9S3 consists of a ne"atively char"ed dischar"e electrode, which is

hun" between to earthed metal plates called collectin" electrodes. Ohen a

hi"h dc volta"e is supplied to the dischar"e electrode an electric field is

produced which ioniGes the "as around the dischar"e electrode. his

phenomenon of dischar"e is called (orona 4ischar"eT. After char"in" the

particles start mi"ratin" towards the earthed electrodes. 'n reachin" the

opposite collectin" plates these ash particles loose their char"e and "et

deposited there. his deposited dust layer is removed by rappin"T at fixed

intervals. his dust then falls into hoppers and ash$handlin" process iscarried out.

Boi'er

he boilers set up in ?alco 4aman5odi at its steam and power "eneration

plant


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air to support combustion

Out+ut%: -

initially the steam "enerated by the boiler was used to meet the

re#uirements of the plant i.e. he process of alumina refinin" but "radually

it was seen that steam produced could be further utiliGed to "enerate poweras a by product. hus the outputs of the boiler now are

steam for the process of alumina refinin"

power as a by product

residual products


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his saturated steam is now fed into the super heater placed inside at

the top of the boiler

;inally the super heated steam at *+/ Rc is fed into the main streamline.

his is the main steam header. his header is now the input to the turbines

hence aidin" in power "eneration.

Air +at,: -

?ow any fuel in any form is brin" in5ected in to the boiler chamber it

catches fire or under"oes combustion instantaneously.

hus in order to control this combustion there are some very elaborate

arran"ements

Boiler is always kept at a ne"ative pressure, so that pressure does not

increase to an explosive value.

3roducin" a forced air draft does this.

Fue' +at,: -

he fuel used in the boiler is of two types. 'ne is the fuel oil and the

other is the pulveriGed coal. (oal is used as a fuel as it is less costly

compared to fuel oil. But the fuel oil has its own si"nificance. Since the coal

cannot be used for combustion as it will result in improper combustion. So

7;' is first used to attain a necessary temperature in the boiler of about H&&

Rc and then coal dust of 0&& mesh siGe is in5ected into the boiler after this

temperature is attained. Initially >4' was used to attain i"nition

temperature in the boiler for firin" 7;' and then coal.

"ariou% co(+onent% and t,eir &unction%: -

Econo(i4er:preheats the water before sendin" to the boiler drum.

Stea( dru(: contains both steam and water pumped in there by theboiler feed pump.

Ban5 tu*e%:connect the steam drum and the mud drum

Mud dru(:It is preheated by flue "asesand contains water at very

hi"h pressure.

eaerator c,a(*er: - it dissolves the oxy"en present in the

demineraliGed water comin" from the 4: planteaerator tan5: water from the deaerator chamber is stored in the

deaerator tank


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Ma5e u+ 3ater tan5: it is filled with condensed steam from the return

steam line received throu"h the return steam lines. It also receives ( from

condensate extraction pumps

$ind *o6) contains heated air from the air pre heater. It provides air in

the proper proportion for complete combustion in the boiler.

Air +re ,eater: it is a heat exchan"er in which air temperature is

raised by transferrin" heat from flue "ases.

Scanner: to check whether the fireball has been established or not we

need to constantly monitor the interior of the boilers. thus scanners have

been installed in order to check the temperature and pressure

Scanner air &an%: in order to keep the scanners cool and clean the

"lass surface is blown by blasts of cold air continuously. hus for coolin"

and pur"in" scanner air fans are used

Tur*ine

he workin" steam flows axially throu"h the sin"le casin" extraction

back pressure. he emer"ency stop valves are arran"ed on the casin" at the

inlet, their purpose bein" to shut off the total steam flow, the boiler to the

turbine in the shortest possible time. he live steam flows trou"h the

emer"ency stop valve housin"s, which are welded on to the side of the

turbine casin", to the hp control valve chest. he control valves re"ulate the

steam flow throu"h the turbine accordin" to the load demand.

he bladin" both in the hi"h pressure and low pressure parts of theturbine is of the impulse type with hi"h reaction. hese parts serve as

re"ulatin" sta"es.

After expansion throu"h the hp part some of the steam is let off

throu"h the two extraction steam mains. ;or isolatin" the turbine from the

mains an extraction stop valve is provided which operates in the same way

as the live steam emer"ency stop valves. Its purpose is to isolate the turbine

from the extraction steam mains in the case of shutdown and thereby avoidsteam flowin" back into the turbine


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he pressure at the point of extraction is "overned by the >3 control

valves. he steam flow throu"h the >3 part is related to the extraction steam

#uantity in such a way that the pressure at the extraction point is kept

constant within the desi"n ran"e. he hp and >3 control valves are each

positioned by a hydraulically operated relay cylinder via linka"e system.

he turbine outer casin" is horiGontally split. he hp and lp steam

chests are cast inte"ral with the top half. hese cylindrical steam chests are

arran"ed transversely with two side assembly openin"s. In the hp steam

chest these openin"s also connect with the emer"ency stop valves. wo

further top openin"s allow further installation of the two valve spindles.

he steam passes via the diffusers and the hp inner casin" noGGle

bowls to the re"ulatin" sta"e. he inner casin" is not horiGontally split

thereby allowin" optimum dimensions with approximately constant wall

thickness. Besides the noGGle rin" and its lockin" rin" for the mountin" of

the diaphra"ms is built into the hp inner casin". hese diaphra"ms are split

horiGontally and are fixed to the lockin" rin" by radial bolts. hereby free

thermal expansion with exact centerin" is allowed. he axial steam forces on

the diaphra"ms are carried by the inner casin" via the lockin" rin" and its

bayonet lock. he centerin" of this lockin" rin" in the inner casin" is

achieved by axial keys arran"ed around the circumference

he steam pressure downstream of the hp inner casin" is

simultaneously the pressure on the outside of the inner casin" caused by

pressure difference are relatively small, no appreciable thermal stresses

occur throu"h temp differences in the inner casin" as it is surrounded by

steam comin" out of the labyrinth at approximately the live steam

temperature

he hp inner casin" is radially and axially located so as to follow freethermal expansion in all directions. It is supported and located axially and

vertically in the outer casin" near the horiGontal 5oint, for sideways

displacement is prevented by top and bottom fit bolts. he connection to

inlet steam chest is achieved by steam ti"ht flexible rin"s which allow

expansion

he use of the hp inner casin" severely reduces the internal pressure

actin" on the outer casin" therefore the outer casin" flan"es and bolts can bereasonably dimensioned


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he lp inner casin" is arran"ed downstream of the hp inner casin", the

lower steam conditions allowin" it to be horiGontally split.

A collar in the outer casin" retains it in the axial direction almost

without play.

Its centerin" relative to the rotor and the outer casin" is achieved by

horiGontal and vertical keys and centerin" bolts

he diffuser for the low$pressure valves which are necessary for

maintainin" the extraction pressure and for controllin" the lp steam flow are

screwed into and locked in the inner casin". he noGGles which are attached

to two half rin"s are inserted direct in the inner casin" halves. he

diaphra"ms are located I the inner casin" by radial centerin" bolts and

vertical bolts t horiGontal 5oint thereby "uaranteein" free thermal expansion.

In order to eliminate steam leaka"e between the rotor and inner casin"

with closed lp control valves a labyrinth seal is provided which operates as a

shaft "land.

As the turbine rotor and outer casin" are independently supported by

the bearin" pedestals an exact ali"nment of both elements is necessary. Since

the rotor position is determined by the bearin"s the thermal expansion must

be taken into account when supportin" the outer casin". he vertical position

of the casin" is determined by paw supports, the play under the heads of the

bolts holdin" the paws to the bearin" pedestals allows transverse expansion

of the outer casin" relative to the bearin" pedestals. he ali"nment of the

outer casin" in the horiGontal plane is achieved by lower casin" "uides

which are so constructed that the outer casin" can freely move up and down

he exhaust and bearin" pedestal is fixed to the sole plates since the

lower casin" and the bearin" pedestal do not allow for axial movementsbetween casin"s and bearin" pedestals, thermal expansion of the casin"

pushes the front bearin" pedestal forward, sideways movement of the

bearin" pedestal is prevented by axial "uide keys. he bearin" pedestals

cannot twist tip or lift.

he turbine rotor is manufactured from an alloy steel for"in". he

formation of the blades direct from the rotor material allows for hi"h blade

loadin". he 5ournal bearin"s for the rotor are located in the bearin"pedestals. Oith the front allocated in the bearin" pedestal also contains the

thrust bearin" which rotates the turbine rotor axially and absorbs axial thrust


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A tooth couplin" connects the turbine rotor to the driven machine and

prevents carry over of axial thrust and bendin" moments.

he balance piston partially compensates the axial thrust as the axial

thrust also depends on the turbine load the remainin" thrust is taken by the

thrust bearin" at the same time the balance piston labyrinth seals the

pressure in the wheel chamber a"ainst the "land steam pressure.

he bladin" consists of a hp and lp impulse sta"e which allows partial

arc admission fro "ood flow re"ulation, the remainin" sta"es and impulse

sta"es. he radial and axial clearances are so dimensioned that add hi"h

reliability in service with best utiliGation of the available heat drop is

achieved

he turbine is hydraulically "overned

he over speed trip is to interrupt steam admission to the turbine as

soon as the speed becomes excessive.

3ressure measurin" points on the various steam spaces are provide for

supervision, thermometers on the bearin" oil return lines allow for re"ular

bearin" checks.

Lu*rication %0%te(: - the lubrication system is desi"ned to reduce the

frictional losses and provide ade#uate coolin" arran"ement to the bearin"s

of the turbine and "enerator, couplin" and "earboxes. It furnishes "overnor

and control oil re#uirement s also

he ma5or parts "overnin" the lubrication system are as follows)

:ain oil tank

:ain oil pump

Auxiliary oil pump

9mer"ency oil pump

Jack oil pump

'il coolers

'il filters centrifu"e

TURBO!ENERATOR


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INTROUCTION

In the recent years many basic industries could not meet their

production tar"ets because of lack of availability of power in ade#uate

#uantity. ?on$availability of power has affected production as well as safety

of some of the core industries. >ookin" from this an"le and based upon the

steam re#uirement of alumina extraction process, detailed study was

conducted for suitable selection of !B' 89?9A'S.

(o"eneration increases the cycle efficiency of the power plant.

AnalyGin" the steam and electrical load pattern of the entire plant, three %+./

:O extraction 3 sta"e and from the exhaust of this sta"e at a pressure of H k"S# cm is

fed to the alumina process as per re#uirement. he 3$C expansion of the

steam inside the turbine determines the work done by the turbine. In turbine

the thermal ener"y of the steam is converted into mechanical motion of theturbine.

he mechanical ener"y of the turbine is used to drive a cylindrical pole

-&&&$rpm "enerator throu"h a "earbox of /-&&-&&&. he stator consists of

the stationary hi"h volta"e circuit and the rotor forms the low volta"e

excitation or the field circuit.

;or an 9:;volta"e to be induced in a conductor as per faradays laws ofelectroma"netic induction$ i.e. if the flux linkin" with a conductor chan"es

an 9:; is induced in the conductor and ma"nitude of the induced 9:;

depends on the rate of chan"e of flux linka"es.


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thereby avoidin" steam flowin" back to the turbines causin" over speedin"

of the turbine due to reverse flow.

he >3 control valve controls the backpressure at the extraction

branch. he steam rate throu"h the >3 steam is matched to the extraction

rate in such a way that the pressure is kept constant within the desi"ned data.

A hydraulically operated relay cylinder positions the 73 and >3 control

valves and a labyrinth "land separates both the drum bleedin"s. he turbine

rotor is manufactured from an alloy steel for"in". he formation of the

blades direct from the rotor material allows for hi"h blade loadin". he

Journal bearin"s for the rotor are located in the bearin" pedestals. he front

bearin" pedestal also contains the thrust bearin" which locates the turbine.

A tooth couplin" connects the turbine rotor to the driven machine and

prevents carry over of axial thrusts and bendin" moments.

TURBINE !O"ERNIN! SYSTEM

urbo "enerator is e#uipped with hydraulic "overnin" system. his is

desi"ned to control the speed of urbo "enerator set at varyin" electrical

loads and extraction steam #uantities.

;or control purpose sin"le casin" backpressure turbine with one

controlled extraction has been divided internally with steam "lands into two

parts hi"h$pressure part and low$pressure part. In each part of the turbine

steam flow is re"ulated by a set of steam control valves. he amount of

openin" of each valve is controlled by the hydraulic si"nal 3 parts of the turbine is the same he SC IC"overnor controls the turbine speed and maintains it at a constant value in

accordance with the functional relationship represented by its characteristic

line. he pressure of the secondary oil dischar"ed at the "overnor output side

forms the input si"nal that acts on the control piston of the servomotor.

he followin" mechanical protections are inbuilt into the "overnin" system.

%. 'ver speed protection. Q Set between + to %&E above the rated

speed.0. >ow lube oil pressure protection. Set at &.2k"cm0".

-. 7i"h back pressure protection. Q Set at 2.0 k"cm0 ".

*. 7i"h extraction pressure protection. Q Set at %0.0 k"cm0 ".


23/98


24/98

moisture, the use of a clarifier is all that is necessary to purify. If, however,

the oil contains some moisture, this will settle to the bottom of the "ravity

throu"h, to"ether with the solids. As additional wet oil is flowed throu"h the

trou"h, the layer of water in the bottom will build up until eventually the

trou"h will be full of water. If wet oil is still fed to the trou"h, it will merely

flow across the top of the water layer and the oil will dischar"e without the

water havin" separated from the oil.

Se+aration:

he term separationT is used to describe the result of "ravity or

centrifu"al force actin" on two li#uids, such as oil and water. A centrifu"al

separator is one that is ad5usted to continuously separate and dischar"e these

li#uids. Since this force is also actin" on any solids present, clarification

takes place at the same time throu"h the deposit of these solids present

clarification takes place at the same time throu"h the deposit of these solids

a"ainst the wall of the bowl. Oater is fed first when the machine


25/98

$ A thruster converter used in - sections for redundancy to convert

the A( to 4( for feedin" the rotor circuit alon" with all

associated protection, coolin" and control systems

$ A field breaker for switchin" on the excitation supply on 4( side

with field dischar"e resistor to avoid over volta"es when field

breaker opens, it is a make before break contact

$ A field flashin" contactor to provide the initial excitation system

re#uirements throu"h a station battery which automatically

switches off as soon as the "enerator output volta"e reaches 2&E

of the rated volta"e.

$ A series compoundin" transformer alon" with rectifier circuits to

provide -&E of the excitation re#uirement durin" normal

operation and to provide additional excitation re#uirements for a

few seconds in case of a fault in the system i.e. to enable the

"enerator to sustain if the fault is cleared instantaneously. he

ma"nitude of the supportin" excitation in case of a fault supplied

by the S( is proportional to the ma"nitude of the fault current

fed by the "enerator it self, it is a basic re#uirement in case of

isolated networks and in systems operatin" in island condition.

$ An Automatic volta"e re"ulator to control the excitation circuits

to maintain the output volta"e constant at set reference value.

AUTOMATIC "OLTA!E RE!ULATOR

he automatic volta"e re"ulatorUs functions are carried out by the

different modules that have been built into it circuitry. he functions of these

modules and their operation mechanisms are discussed briefly below.

he AC is desi"ned to control the output volta"e of the "enerator at

set value throu"h a closed loop control comprisin" of inputs from the 3, (

of the "eneratorIt has various limiter circuits that override the AC si"nal to ensure stable

performance of the "enerator .

hey are rotor current limiter, limitin" the rotor current to a set value if

brin"in" irrespective of the AC si"nal exceeds the set value and AC

can take over only when the current has come down below the set

value of the rotor current limiter.

Stator current limiter to limit the "enerator output current to set value

overridin" the AC increasin" error si"nal and AC can take over only

when the current has come down below the set value


26/98

otor An"le limiter to prevent the rotor fallin" out of step overridin"

the AC increasin" error si"nal and AC can take over only when the

current has come down below the set value

?$0 limiter to limit the rotor current in case of failure of O' thyristor

brid"es

79 AC IS 4ICI494 I?' O' S9(I'?S '?9 $$A!'

(7A??9> ;' ?':A> '39AI'? A?4 A :A?!A> (7A??9>

;' 9SI?8 3!3'S9 A?4 ;' 9:989?(N '39AI'?.

here is a provision for automatic chan"eover from A!' to :A?!A>

channel in case of any problem in the excitation circuits and in such a case

to ensure sur"e free operation durin" chan"eover the :anual channelreference is made to automatically follow the auto channel reference

throu"h a follow up circuits, pulse comparison circuits

he :anual channel functions in an open loop control throu"h a manual

limiter and field current re"ulator

he 3ulse "enerator, intermediate pulse amplifiers are duplicated one each

for A!' :A?!A> channel

'ther important cards like pulse supervision module, pulse distribution

board and necessary power supply modules, transformers, filters, Colta"e

relays, Auto potentiometers and manual reference potentiometers, :atchin"

and feed back modules, (ards for >o"ic circuits and annunciations, fault

indications, timers etc are provided to ensure fool proof operation and

dynamic stability of the re"ulator

he pulse final sta"e and its power supply, thruster and its coolin"

circuitry, pulse transformers etc are in - different and independent sections

FUNCTIONS OF A"R MOULES IN AUTO 7 MANUAL

C1ANNELS

Matc,in2 7 Feed*ac5 Modu'e:

It is used in both :A?!A> and A!' mode It is used for matchin" the :A?!A> reference to the runnin"

A!' 3' reference, when 8 is runnin" on A!' mode, on a

continuous basis. his is necessary for sur"e free operation of 8


27/98

when a chan"eover takes place from A!' to :A?!A> due to

any reason.

he input is used for matchin" the :A?!A> reference to the

runnin" A!' 3' reference, when 8 is runnin" on A!'

mode, on a continuous basis, i.e. with 3% relay ener"iGed. Ohen 8

is runnin" in :A?!A> this input is inverted and si"nal is fed toAC i.e. with 30 relay ener"iGed.

It has an sin"le input which is available at test point / of ! &/

'utput for ?ull balance voltmeter is available at test point * of !

&/.

ero volt reference available at test point -& of ! &/.

Fo''o3 u+ contro':

It functions only when AC is in A!' mode It is employed everywhere one must influence a controlled variable with

discontinuous final control elements. 7ere it is utiliGed to "ive si"nals to

raise lower the :A?!A> reference to follow the A!' 3' reference.

And thereby ensurin" sur"e free operation in case of chan"e over from

Auto o manual channel

It has an electrical interlockin" so that both raise lower si"nals are not

available at the outputs simultaneously.

'utput raise lower is available at test point 0/ 0* of ! &/.

Stator current 'i(iter8 Inte2rator:

It controls the AC in A!' mode

>imits stator current in synchronous "enerators.

It has a I sin


28/98

his unit has its power supply in built

Rotor current 'i(iter:

It controls the AC in A!' mode

>imits rotor current in synchronous "enerators.

?ormally limits the current to set value, but in case of ?$0 inautomanual it is brou"ht down to a set value and A!' mode

In A!' its output is delivered to AC throu"h a contact in manual

limiter

In :A?!A> mode output is delivered to manual limiter which in turncontrols the field current, but the priority of field current is there over

this in both :A?!A> and A!' mode .

>imits electrically the an"le between the stator rotor. It has a

provision for switchin" ';; the output.

Instantaneous action and increases field current t to keep the machine

fallin" out of step

Manua' 'i(iter

It is used in both :A?!A> and A!' mode

>imits rotor current in


29/98

Fie'd current re2u'ator

It is used in :A?!A> mode

o limit the rotor current re"ulate the field current.

his is used to re"ulate current to set value especially when theexcitation system has a series compoundin" transformer.

e' a'+,a 8 Pu'%e Co(+ari%on Unit

It is used for comparison of firin" pulsesAuto and :anual (hannels !sed for pulse comparison to compare the output pulses of both Auto

manual channel in order top keep the manual channel analo" output

e#ual to the Auto channel analo" output so that sur"e free chan"e over

from Auto to :anual is ensured in case of any abnormality, this isachieved throu"h :atchin" ;eedback :odule and follow up

control.

Pu'%e %u+er)i%ion unit

It is used in A!' mode

3icks up after set delay in case of missin" pulses, asynchronous pulses

with an >94 indication, and in turn blocks the pulses of the

intermediate pulse sta"e or and cause protective chan"eover to :anual(hannel

(han"e over to :anual channel disables this unit

Contro' A(+'i&ier 8 A"R

It re"ulates the output volta"e of the "enerator and keeps it constant as

per the set value if all parameters are with in limit

4oes not have any internal power supply

eceives input from reference circuit, limiters, actual value circuit

comprisin" of sensed 3 and ( input values and delivers an output

volta"e proportional to the difference of actual value and reference

value to "rid control unit after considerin" the inputs from limiters.

It has a provision for reactive power compensation to take care of the

drop in the unit transformer.

It has a fre#uency dependent circuit to control the output volta"esproportional to fre#uency when the "enerator is runnin" at fre#uencies

lesser than the rated value.

It has "ain reducin" circuitry to minimise the oscillations in output


30/98


31/98

C,anne' c,an2eo)er &ro( AUTO to Manua'

It takes place automatically as a result of 3rotective chan"eover si"nal

due to any abnormal operation of the excitation system the re"ulator

as sensed by the lo"ic circuitry

(han"e over carried out from the control desk or re"ulatorintentionally

4urin" chan"eover the pulses of the unused channel are blocked

electronically and for the channel comin" into service the pulses are

released electronically

In :anual channel the otor current limiter, Stator current limiter,

inte"rator are not effective

'nly the load an"le limiter is effective in addition to :anual limiter

when the re"ulator is operatin" in manual channel.

Po3er %u++'0

he power supply for the electronics is obtained from the excitation

transformer throu"h a re"ulation supply transformer after rectificationre"ulation stabilisation in the power supply :odules

;or Auto channel O' power packs !? 0&&2 and !?0&&* are

provided. !? 0&&% and !? 0&&* are functional upto minimum of -&

E &f the rated supply volta"e

!? 0&&2 is functional upto $ -& E of the rated supply volta"es and

supplies $ %/ C) /C) 0* C stabilised power supply for limiters,

Slip stabilisation circuits, Supervision modules. It is provided with an

input :(B to open in case of 'ver Colta"e 'ver (urrent. It has an

circuit to monitor output under volta"e and indication by an >94

which does not "low in case of under volta"e and in case of output

under volta"e causes chan"e over to manual channel

;or :anual (hannel only power pack is provided namely !? 0&&*

9ach 3ulse output Sta"e has its own power pack !? 0&&%


32/98

Synchronous Colta"e for pulse "eneration is obtained from a

Synchronous transformerof ratio %*&-+& C A( whose primary is

connected to the excitation transformer secondary a filter. A Colta"e

relay supervises the synchronous volta"e

;or the purpose of testin" the re"ulator, an Auxiliary supply isprovided throu"h a Auxiliary transformer of ratio *%/ C -+&CA(

from an external source

he supply for coolin" fans of the thyristor cubicle is obtained from

the excitation transformer throu"h a fan supply transformer of ratio

%*&-+&C A(

*+ Colt 4( is obtained throu"h a= %%& C4( *+C 4( 4( $4(converter KxL%2%a, and b= %*& C A( *+C 4( throu"h an A( 4(

converter KxL%2%a. All the 0 outputs are connected in parallel And

are used for ! trippin"M !c for "eneral control circuitsM !s for

si"nalisation

0* Colt 4( is obtained throu"h a= %%& C4( 0*C 4( 4( $4(

converter KxL%2&a, and b= %*& C A( 0*C 4( throu"h an A( 4(

converter KxL%2%a. c= 0* C A($4( linear power supply. All the -outputs are connected in parallel and are used for lo"ic cards

"o'ta2e Re'a0 UN 999

:onitors the output "enerator volta"e

8ives si"nal for blockin" the pulses of the 8I4 control unit if the op

volta"e is less than -&E of the rated system volta"e

Switches ';; the field flashin" e#uipment if the 'p volta"e is more

the n 2&E of the rated system volta"e

Pu'%e &ina' Sta2e UN ;99

7as its own supply unit

Supplies the pulses to the thyristor throu"h pulse transformers

Serie% co(+oundin2 tran%&or(er


33/98


34/98


35/98

@ty. of "land steam at inlet %**+ k"hr steam I> pipes (S, SA %&H 8r B

Impin"ement plate SS, SA 0*& 3 -&*

Stea( =et e=ector &or !SC

Oorkin" steam pr.temp %%ata0H*&c

Steam consumption %/H k"hr.

Suction pr. &.+/ ata

Suction moisture 0/& k"hr

Oi' Coo'er

@ty. of oil H+.%0 m-hr.

'il I> and '> temp /L.L*/&c

3r. 4rop in oil side %.- k"cm0

@ty. of coolin" water %&& m-hr.

(O I> and '> temp -H*&.%&c

(oolin" surface %&& m0

ube siGe


36/98


37/98

power plant was commissioned later to efficiently utiliGe the steam bein"

produced at the refinery complex. It ensures an uninterrupted power supply

to the refinery.

An essential piece of e#uipment for the power plant is the turbo$

"enerator. he different departments of the power plant function to ensure

the smooth functionin" of the 8.

he basic function of an Automatic Colta"e e"ulator and the series

compounded transformer is to increase the efficiency of the turbine and to

prevent trippin" of the turbine durin" minor malfunctions in the "rid.

SAFETY

In todays world Safety, 7ealth and environmental issues have become a

matter of serious concern for all societies, which no country can afford to

disre"ard in the process of development. As industry has evolved, si"nificant

advances have been made in overcomin" many of the challen"es to the

safety, health and well bein" of the workin" people. Net it is estimated by

I>' that more than two lakh work related death occur each year all over the

world. In addition, a lar"e number of workers are victims of work related

accidents and occupational diseases. 9stimate also indicates that the

economic conse#uences of accidents and diseases at work represent at least

%E of the 8?3 of our nation. It is therefore necessary that Safety, 7ealth

and 9nvironmental consciousness become intrinsic to our thinkin" and

development process. 3reventin" or minimiGin" accidents, ill health and

pollution, avoidin" wasta"e and conservin" no$renewable resources must

become our personal and public "oals.

'bservance of safety norms is of vital importance as any lapse on this

account many not only result in loss of e#uipments and machinery but also

loss of precious human life. Safety must therefore be "iven utmost priority

in every sphere of our life, be it in work place or at home.

?alco bein" an inte"rated pro5ect involvin" minin", chemical processin",

smeltin" and power "eneration, a hi"h de"ree of awareness re"ardin" safety,

health and environmental is must at all levels. :ore so, at this particular5uncture, when we are "oin" to commission a massive expansion almost

doublin" our activities, the pressure to achieve hi"her efficiency on order to


38/98

remain afloat in the "lobal market would certainly brin" about increased

exposure of our people to industrial haGards.

MEASUREMENT TA@EN OUR PLANT

%. INSPECTION OF PLANT 7 E#UIPMENT:Safety inspection of

3lant and 9#uipment are carried out re"ularly to identify unsafe

practices and usa"e of safety appliance.

0. INSPAECTION OF EFERENT AREAS:3eriodic inspections of

different areas are bein" conducted and the defects which are noticed

durin" inspections are hi"hli"hted, action plan and are rectified within

the time bound plan.

-. ELIMINATION OF UNSAFE CONITION:he systematic way

of identifyin" unsafe conditions and makin" time bound action plans

for eliminatin" them has been "iven top priority to provide a safe and

haGard free environment. A lar"e number of various modification 5obs,

rectification of unsafe conditions, safety committee recommendations

are bein" undertaken durin" this period.

*. SAFETY APPLIANCES: sincere efforts are made in different

4epartments at the time of re"ular inspection t motivate and enhance

the use of personal protective 9#uipment by safety committee

:embers and Safety 4epartment.

/. ISTRIBUTION OF FIRST AI BOXES:;irst Aid Boxes alon"

with necessary contents were issued to -+


39/98

set us on all sides. Nearly, several lakhs of employees are in5ured in

factories due to accidents. Annexure % "ives the details of accidents in

India durin" %L2+ to %L+%.

hese accidents represent a social loss of "reat ma"nitude in the form of

pain, loss of earnin" capacity and cost due to disturbance to economic

efficiency. he painted sufferin" of the in5ured as well as the emotional

loss to the victims of the fatalities and accidents causin" permanent

disfi"urements or disabilities are impossible to be summed, throu"h

partially, no fi"ures are available in terms of the total cost of accidents in

our factories. o the mana"ement, it is the direct costs for meetin"

medical expenses, compensation of disablement benefits to the in5ured or

their families and also the various other indirect costs due to the

interference caused by accidents, which are "enerally taken rou"hly as for

items the direct costs. o the society, the economic cost is in terms of loss

of productive capacity and the cost of maintenance of the in5ured and

their families throu"h social security schemes or throu"h public or private

charities.

In the absence of date relatin" to total economic losses due to accidents,

makin" use of the fi"ure published by the >abour Bureau can have a very

approximate idea. Simla of claims paid by the employees of State

Insurance (orporation in respect of establishments covered by the

employees sate Insurance Act. he total cost of payments for temporary,

and permanent disablements and dependants benefits paid by the

(orporation durin" the years %L2+ to +% in accident cases covered by the

Scheme was on an avera"e s. 0& crores. his forms only one part of the

direct costs. In as much as the cost of providin" medical care has not been

included. ?o fi"ures are available in respect of the latter. All the same, for

our purpose., it can be indicated by usin" the multiplication factor

su""ested by 7einrich


40/98

CLAUSES OF ISO 99 :

*.% :A?A89:9? 9S3'SIBI>IN

*.0 @!A>IN SNS9:S

*.- ('?A( 9CI9O

*.* 49SI8? ('?'>

*./ 4'(!:9? A?4 4AA ('?'>

*.H 3!(7ASI?8

*.2 ('?'> '; (!S':9 Q S!33>I94 3'4!(

*.+ 3'4!( I49?I;I(AI'? A?4 A(9ABI>IN*.L 3'(9SS ('?'>

*.%& I?S39(I'? A?4 9SI?8

*.%% ('?'> '; I?S39(I'?, :9SA!I?8 A?4 9S

9@!I3:9?

*.%0 I?S39(I'? A?4 9S SA!S

*.%- ('?'> '; ?'?$('?;':I?8 3'4!(

*.%* ('9(IC9 A?4 39C9?IC9 A(I'?

*.%/ 7A?4>I?8, S'A89, 3A(KA8I?8, 39S9ACI'? A?4

49>IC9N

*.%H ('?'> '; @!A>IN 9('4S

*.%2 I?9?A> @!A>IN A!4IS

*.%+ AI?I?8

*.%L S9CI(I?8


41/98

*.0& SAISI(A> 9(7?I@!9S

ISO 99 : ;999

CLAUSES

%.& S('39

%.% ?':AIC9 9;99?(9S

%.0 @!A>IN :A?A89:9? SNS9:

%.- 9S'!(9 :A?A89:9?

%.* 3'4!( 9A>ISAI'?

%./ :9AS!9:9?, A?A>NSIS A?4 I:3'C9:9?

ISO 99 : ;999

#UALITY MANA!EMENT SYSTEM RE#UIREMENTS

%.H @!A>IN :A?A89:9? SNS9:

%.2 89?9A> 9@!I9:9?S

%.+ 4'(!9:?AI'? 9@!I9:9?S

%.L 89?9A>

%.%& @!A>IN :A?!A>

%.%% ('?'> '; 4'(!:9?S

%.%0 ('?'> '; @!A>IN 9('4S

ISO 99 : ;999


%.%- :A?A89:9? 9S3'?SIBI>IN%.%* :A?A89:9? ('::I:9?

%.%/ (!S':9 ;'(!S


42/98

%.%H @!A>IN 3'>I(N

%.%2 3>A??I?8

%.%+ @!A>IN 'BJ9(IC9S

%.%L @!AKIN :A?A89:? SNS9: 3>A??I?8

%.0& 9S3'?SIBI>IN, A!7'IN ('::!?I(AI'?

%.0% 9S3'?SIBI>IN A?4 A!7'IN

%.00 :A?A89:? 939S9?IC9

%.0- :A?A89:9? 9CI9O

%.0* 89?9A>

%.0/ 9CI9O I?3!

%.0H 9CI9O '!3!

ISO 99 : ;999

#UALITY MANA!EMENT SYSTEM - RE#UIREMENTS

%.02 9S'!(9 :A?A89:9?

%.0+ 3'CISI'? '; 9S'!(9S

%.0L 7!:A? 9S'!(9S

%.-& 89?9A>

%.-% (':399?(9, AOA9?9SS A?4 AI?I?8

%.-0 I?;AS!(!9

%.-- O'K 9?CI'?:9?

ISO 99 : ;999


%.-* 3'4!( 9A>ISAI'?

%.-/ 3>A??I?8 '; 3'4!( 9A>ISAI'?

%.-H (!S':9 9>A94 3'(9SS9S

%.-2 499:I?AI'? '; 9@!I9:9?S 9>A94 ' 793'4!(

%.-+ 9CI9O '; 9@!I9:9?S 9>A94 ' 79 3'4!(


43/98

%.-L (!S':9 ('::!?I(AI'?

%.*& 49SI8? A?4 49C9>'3:9?

%.*% 3!(7ASI?8

%.*0 3!(7ASI?8 3'(9SS

%.*- 3!(7ASI?8 I?;':AI'?

%.** C9I;I(AI'? '; 3!(7ASI?94 3'4!(

%.*/ ('?'> '; 3'4!(I'? A?4 S9CI(9 3'CISI'?

%.*H CA>I4AI'? '; 3'(99S9 ;' 3'4!(I'? A?4 S9CI(9

3'CISI'?

%.*2 I49?I;I(AI'? A?4 A(9ABI>IN

%.*+ (!S':9 3'39N

%.*L 39S9CAI'? '; 3'4!(

%./& ('?'> '; :'?I'I?8 :9AS!I?8 49CI(9S.

ISO 99 : ;999


%./% :9AS!9:9?, A?A>NSIS I:3'C9:9?

%./0 89?9A>

%./- :'?I'I?8 A?4 :9AS!9:9?

%./* (!S':9 SAIS;A(I'?

%.// I?9?A> A!4I

%./H :'?I'I?8 :9AS!I?8 '; 3'(9SS9S

%./2 :'?I'I?8 :9AS!9:9? '; 3'4!(S

%./+ ('?'> '; ?'?$('?;':I?8 3'4!(

%./L A?A>NSIS '; 4AA

%.H& I:3'C9:9?S%.H% ('?I?!A> I:3'C9:9?

%.H0 ('9(IC9 A(I'?


44/98

%.H- 39C9?IC9 A(I'?

#UALITY MANA!EMENT PRICIPLES

AOPTE FOR ISO 999 : ;999D

%.H* (!S':9 Q ;'(!S94 '8A?ISAI'?

%.H/ >9A49S7I3

%.HH I?C'>C9:9? '; 39'3>9

%.H2 3'(9SS A33'A(7

%.H+ SNS9: A33'A(7 ' :A?A89:9?

%.HL ('?I?!A> I:3'C9:9?

%.2& ;A(!A> A33'A(7 ' 49(ISI'? :AKI?8

%.2% :!!A> B9?9;I(A> S!33>I9 9>AI'?S7I3


45/98

CONTINUAL IMPRO"EMENT

Improvement means settin" hi"her standards and achievin" the same.

(ontinual improvement refers to on"oin" efforts for improvement. !sually

what is understood is improvement involvin" everyone in the or"aniGation.

(ontinual improvement is also know as kaiGen.

KAI 1 Improvement

9? 1 8ood, for the better

7ow can you contribute to continual improvement)$ hrou"h individual

su""estions or by "roup activity like #uality circles.

;or improvement in the followin" areas.

:akin" the 5ob easier i.e. eduction in man hours.

emovin" drud"ery from the 5ob.

emovin" nuisance from the 5ob.

:akin" the 5ob safe.

:akin" the 5ob more productive.

Savin" in time cost.

7ow can continual improvement be achieved ) $ By settin" hi"her standards

of work, achievin" the same, maintainin" it and improvin" standards.

esult )$ Safe, eliable processes that runs automatically or in a

standardiGed why without intervention by people.


46/98

O"ER "IE$ OF MINES

INTROUCTION

3anchapatmali bauxite deposits have an indicated reserve of -%2

million tones. It is divided into three blocks. hey are north block and

central block. he present minin" is concerned with sector % of central

block. he annual production of bauxite is 0.* million tones per annum .A

downhill cable belt system is established to carry one to the stockpile at

alumina plant.

SALIENT FEATURES OF MINES

>en"th of conveyor %*.HH%km

Oidth of conveyor belt %.%-2mm

;all of conveyor belt -*&mts

ated capacity of conveyor belt %+&&tph

3ercenta"e of Alumina *0./E

3ercenta"e of silica 0.-E

ype of crusher 4ouble ooth roll crusher

>ump siGe before crushin" +&&mm

>ump siGe after crushin" %/&mm

MININ! MOEL


47/98

;or drawin" up annual production pro"ramme, indicatin" the #ualities

and #uantities and for studyin" in advance the various overburden and

bauxite faces, a numerical minin" model is made by transformation of

information obtained from the deposit model in the 8eostatistical studies. It

consists in a breakdown of the deposit to a %&&mD%&&m kri""ed "rid. 9ach

of such panel is further divided to a block of over burden a block of bauxite

to be mined in first phase and thick block of bauxite to be mined in second

phase. After allowin" for unminable areas locked up in minin" infrastructure

and peripheral barriers and Applin" the loss and dilution factors for each

such panel the followin" parameters are determined.

onna"e of overburden to be removed.

onna"e of minable ore in each phase with Al0'- and Si'0 content

showin" of minable bauxite between the two phases is done keepin" in

view mass minin" in firs phase


48/98

selectively in * mtr thick slices. 'n of the lar"e siGe wheel loader of

hydraulic excavators has been found suitable for loadin" operations in first

phase. he second phase re#uires backhoe hydraulic excavators for selective

minin".

?ormally the width of the trenches are kept more than *& mts for efficient

use of heavy machineries and the level differences between ad5acent

trenches, is kept less than *mts. he faces of the trenches are systematically

advanced to maintain a XSaw ooth (onfi"uration of work sites, which

ensure ade#uate flexibility in minin" operations and safety to the e#uipment

deployed.

A %/ mt wide peripheral barrier around the deposit on the ed"e of plate is

left to constitute a safety barrier for the machines. his also serves to locate

the peripheral road and helps in containin" most of the rainwater with in the

mine. It provide a natural curtain for the mine excavators form surroundin",

which help preservin" the natural beauty of the re"ion apart from

minimiGin" the possible dust storms in the minin" area.

he modified trench method of minin" has the followin" advanta"es)

%. Cersatility Q :inin" faces are separated and interchan"eable. hey

are numerous and can be worked continently for effective "rade

control of .'.:. feed.

0. Adaptability to 8eolo"ical disturbances on the deposit results in low

loss and dilution factors.

-. (onvenient work site dimensions permit concentration of minin"

e#uipment and minimiGed travel.he minin" area is divided into trenches in a alphabetical order from A to

@. ocks containin" Alumina less than -/E or Silica more than /E are


49/98

left. It is proper blendin" that the re#uired percenta"e of *0./E Alumina

and 0.-E silica is obtained.

CRUS1ER AN CON"EYOR SYSTEM

he bauxite after minin" is fed to the crusher the main purpose

is to reduce the siGe ran"e from +&& mm to %/& mm. he avera"e

moisture content of bauxite is +./E

PRIMARY CRUS1ER

he bauxite is fed to the hopper by dumper either from the stockpile

or directly from the mines. ;rom hopper the material is transformed to

crusher throu"h Appron ;eeder %. It is driven by a //kw dc motor. he

crusher is a double tooth roll crusher and it has an crushin" capacity of

L&& tph from +&& mm fed siGe to %/& mm product siGe. his is powered

by 0D0&& KO A( motors .he tow rollers run at different speed


50/98


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52/98

A!SA>IA=

&L ':B9AS = :? -.-

%& '?C9 4A(7I

S!I?A:

S!A>(' -.&

%% 49>3AK IA=

A>('A

J'I? C9?!9

-.&

%0 AIA >9N

3A %.-

%+ B9A4 ?!!A>>9N

('A %.-

%L OI>>'4A>9 IA=

A>('A %.0-

0& KIK!I?9 JA:AIKA A>(A? %.*

!S9S, A33>I(AI'? A?4 3'39I9S '; A>!:I?I!:

A>!:I?I!: Q 79 O7I9 8'>4Abundantly available in nature.

+E of 9arths crust comprises Alumimium.

:ost widely used metal in the world after steel.

!ni#ue properties, a versatile metal.

:ost friendly metal Q technolo"ically, economically and ecolo"ically.

3'39I9S '; A>!:I?I!:

Y 8as esistance Y eflectivity Y Stron" Y Anodisable


53/98

Y 4uctile Y 3rintable Y 9mmisivity Y :alleable

Y ecyclable Y ?on$permeable Y >i"ht wei"ht Y

7y"ienic

Y asteless Y 'dorless Y?o sparkin" Y Oorkability

Y (apacity Y ?ontoxicity Y (orrosion resistance

Y :oisture$vapour resistance Y 8rease and 'il resistance

Y 7eat ;lame resistance Y hermal (onductivity.

A33>I(AI'?S '; A>!:I?I!:.

ransport Q >and, Sea, air, Space

Buildin"

4efence

3ower transmission

;ood processin"

3harmaceuticals$tables, 'intments

:ilk 3roducts$yo"hurt, curd, cheese, butter, steriliGed milk.

Sweets Q (hocolates bars, boxes of chocolates, ice creams, chewin"

"um.

7ousehold aluminium foil.

(offee, ea$ vacuum packa"in".

4ried food ) Soups, (ereals, 3otato puree, baby food.

Instant foods.

4rinks Q efreshments, Beer, ;ruit 5uice.

obacco

3et ;ood.

(osmetics

8lues, 3aints, Inkcatrid"es.


54/98

AREAS OF USA!E OF ALUMINIUM PAC@A!IN!

3acka"in";ood 3rocessin" is an important application sector of

aluminium directly involvin" the human society.

Oithstands both heat and cold.

9asy to steriliGe for food and medical applications.

9xcellent barrier a"ainst li#uids, vapours and li"ht.

>i"ht wei"ht, hy"ienic and non$contamination$lon"er shelf life of end

products.

>ac#uer able and printable.

In soft temper has full dead fold properties and ease of shapin".

?ontoxic, 'dorless, tasteless, colourless and hy"ienic.

8ood heat reflectivity !:I?I!: 3A(KA8I?8

9ver thinner :aterial, 9ver stron"er in function.

:aximum results from minimal material investment.

!nlike plastics totally recyclable Biode"radable.

7i"h recovery rate with reduced emission of pollutants.

9ner"y and material savin".

9nsure fuel economy in transportation.

epeated use without loss in #uality.


55/98

7ealth Q Safe 9co$friendly.

A>!:I?I!: I? 79 7!:A? B'4N

;ound naturally Q approx. -/m". $ /&E in the laun"s

0./E in the soft tissue

0./E in the bones.

Impossible to avoid exposure.

Body ad5usted well to the exposure.

3lays no physical role

ypes of exposure )

?atural content, throu"h diet, dependin" on "eo"raphical

area, !:I?I!: ;' (''KOA9Z.

9xcellent conductor of heat.

ransfers heat very effectively and evenly.

Aluminium cookware is li"ht, stron" and durable.

9asily recyclable with extremely hi"h recovery rate


56/98

(onducts heat more efficiently than stainless steel, losses only 2E heat

it receives

Aluminium has excellent cookin" characteristics.

Aluminium cookware dose not impact any taste or odor to food.

Aluminium is safe cookware and a "ood container of food.

It is very easy to fabricate.

It take very "ood surface finish.

Aluminium is #uite neutral. 4oes not "et leached or corroded on

contact with food.

(an be easily lac#uered, anodiGed, plated, enameled prevent attack by

acids.

7i"h ener"y savin".

A>!:I?I!: A?4 79A>7

AlGheimers disease is pro"ressive, de"enerative disease that attacks

the brain and results in impaired memory, thinkin" and behaviour.

9xtensive investi"ations for H& years by reputed health a"encies and

4 establishments have clearly shown that the amount of aluminium

in"ested throu"h cookin" in aluminium utensils is very small and

harmless.

Investi"ations conducted directly on the human brain could not

establish that aluminium causes AlGheimers disease. Ohat Oorld

7ealth 'r"anisation


57/98

4ata are inade#uate to support the hypothesis that exposures to

aluminium in drinkin" water accelerate AlGheimers disease or that

exposures. 9ither occupationally or via drinkin" water, impair

co"nitive function.

here is insufficient health related evidence to 5ustify alterin" existin"

O7' 8uidelines for aluminium exposure in healthy, non$

occupationally exposed humans.

'rdinary environmental exposure to aluminium is safe.

Intake of aluminium throu"h cookware, packa"in" etc. is ne"li"ible

and harmless.

he amount of aluminium in"ested throu"h cookin" in aluminium

vessels is very small.

7as not been demonstrated to pose a health risk to humans.

Any intake of aluminium is promptly excreted.

O7A 79 ;''4 A?4 4!8 A4:I?ISAI'?


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Specially desi"ned preservation system for spent pot lines.

(aptive power plant

9lectrostatic precipitators with advanced intelli"ent controllers and

effective stack emission control.

9fficient burner mana"ement to reduce emission of carbon monoxide.

Ash pond with Gero dischar"e and recyclin" of wastewater.

Co((on (ea%ure% ta5en in a'' unit%

reatment and recyclin" of process wastewater and sewa"e.

e"ular monitorin" of air, water and noise pollution.

e"ular safety and fire audits mock drills etc.

'ccupational health surveys and periodical medical check$up of all

employees.

3romotin" and executin" pro"rammes for socio$economic

development in peripheral areas such as housin", electricity and water

supply, sanitation, road communication, health, education,

a"riculture, vocational trainin", sports cultural activities.

ISO 999

In its #uest for excellence in environmental care the company crossed

a milestone when : complex was certified under IS' %*&&%. Alumina

refinery of the company is the first chemical plant in the country to be

certified under IS' %*&&%.

oday all the four units of the company have achieved IS' %*&&%

certification as detailed below.

Unit ate o& certi&ication certi&0in2 a2enc0


62/98

:ines June 0*, %LLH :s Aspects moody

certification, !k

elinery ;ebruary %&, %LL2 $do$

(pp 4ecember %L, %LL2 :s OI!C, 8ermany

Smelter :ay 0/, %LL+ $do$

;rom ;ebruary 0&&& onwards re$certification of mines refinery by :s

O!C, 8ermany.

he IS' %*&&& certification has not only helped to improve the

ima"e as an eco$friendly company but has also "iven si"nificant financial

benefits. hese benefits have come mostly due to better house keepin"

reduction in waste "eneration and systematic collection for disposal of

wastes and improvement in performance particularly with respect to

consumption norms.

9nvironment mana"ement must be an inte"ral part of every level of

business enterprise successful mana"ement will have to expand its sphere of

influence to embrace a considerably wider concept have environment. he

"rowin" compulsions on account of the environment awareness have forced

the industries to a provocative retrospection of their processes to ensure

compliance of specific emission standards and assure the public that their

productprocess are more eco$friendly.

he 9nvironment mana"ement system


63/98

(onsiderin" the importance and re#uirement mines refinery

units has been certified with IS' %*&&& since %LLH %LL2 respectively

recently we have switched over to O!C as our certifyin" a"ency since

%%.&2.0&&& for compatibility with IS'$ L&&& system also.

COMMITMENT

Oe dedicate ourselves to total environmental mana"ement system for

prevention of pollution and continual improvement for achievin" our

ob5ectives.

he policy and the information on environment protection efforts shall be

shared with public and all interested parties throu"h periodical publications,

booklets, pamphlets posters etc.

(>A!S9S '; BS 22/&, %LL*

%. 9?CI'?:9?A> :A?A89:9? SNS9:

0. 9?CI'?:9?A> 3'>I(N

-. '8A?ISAI'? 39S'??9>

*. 9?CI'?:9?A> 9;;9(S

/. 9?CI'?:9?A> 'BJ9(IC9S A89S

H. 9?CI'?:9?A> :A?A89: 3'8A::92. 9?CI'?:9?A> :A?A89:I? :A?!A>

4'(!:9?AI'?


64/98

+. '39AI' ('?'>

L. 9?CI'?:9?A> :A?A89:9? 9('4

%&. 9?CI'?:9?A> :A?A89:9? A!4IS

%%. 9?CI'?:9?A> :A?A89:9? 9CI9OA

EN"IRONMENTAL POLICY

Ohile committin" to the corporate environmental policy of ?A>('

Alumina refinery, 4aman5odi, resolves to protect and maintain a "reen

and clean environment while contributin" to sustainable socio$economic

development of the re"ion throu"h its activities.

.IS' %*&&% is an internationally accepted standard that lays down the

re#uirements for establishin" implementin" and operatin" an environmentmana"ement system. IS' %*&&%)0&&* has been published on %/th

?ovember 0&&*. It features clarification of re#uirements, ali"nment with


65/98

IS' L&&%)0&&& and chan"es to the text to make it more user$friendly. Some

chan"es are likely to re#uire or"aniGations to review or perhaps amend their

system to ensure conformance with the final version of the new standard.

;or or"aniGations usin" IS' %*&&% for their 9:S and accredited to IS'

%*&&%)%LLH a summary of the key chan"es is provided below.

Co(+ari%on c,art

ISO 99: ISO 99:;99

% scope % Scope

0 ?ormative references 0 ?ormative eferences

- 4efinitions - erms and 4efinition

*.% 8eneral e#uirements *.% 8eneral e#uirements*.0 9nvironmental policy *.0 9nvironmental 3olicy

*.- plannin" *.- 3lannin"

*.-.% 9nvironmental Aspects *.-.% 9nvironmental Aspects

*.-.0 >e"al other e#uirements *.-.0 >e"al and other

e#uirements

*.-.- 'b5ectives ar"ets *.-.- 'b5ectives ar"ets

pro"ramme


66/98

esponse and espones

*./ (heckin" and corrective

action

*./ (heckin"

*./.% :onitorin" and

measurement

*./.% :onitorin" and

measurement*./.0 ?onconformance and

corrective preventive action

*./.0 9valuation and compliance

*./.- ecords *./.- ?onconformity corrective

action preventive action

*./.* 9nvironmental mana"ement

system audit

*./.* (ontrol of records

*././ Internal Audit*.H :ana"ement review *.H :ana"ement review

C'au%e : Sco+e

he scope of the standard has been expanded to include new application in

the 0&&* version of the standard. hey include options to demonstrate

conformity by )

:akin" a self$determination or self$declaration

Seekin" confirmation from parties who have an interest in the

or"aniGation, for instance, customers

Seekin" certification or re"istration of the 9:S by an external

or"aniGation

I(+'ication

An or"aniGation is now re#uired to define the scope of its 9:S. his

scope directly links the mana"ement system with the or"aniGations

activities products and services. he word and determine how it fulfils these

re#uirements related to re#uirements in IS' %*&&% have been added to the

clause *.%. wo thin"s need to be done in this re"ard. ;irstly, define the

scope of the or"aniGations 9:S includin" what activities, operations,


67/98

services and products are included with it. he scope needs to be

documented one possibility could be in the environmental policy. Secondly,

there is a need to evaluate and document how an or"aniGations 9:S fulfils

the re#uirements of IS' %*&&%. his could be done as part of the internal

audit or as part of mana"ement review, as lon" as it is traceable.

C'au%e ?: Ter(% and e&inition%

IS' %*&&%)0&&% includes some definitions not included in the %LLH version.

Some of the definitions in IS' %*&&%)%LLH have also been revise to ensure

they are more consistent with terminolo"y in IS' L&&%)0&&&.

he followin" are the new terms and definitions introduced in IS'

%*&&%)0&&*)

-.% Auditor$ person with the competence to conduct an audit

-.- Correcti)e Action$ Action to eliminate the cause of a detected

nonconformity

-.* ocu(ent$ Information and its supportin" medium

-.%* Interna' Audit$Systematic independent and documented process for

obtainin" audit evidence and evaluatin" it ob5ectively to determine the

extent to which the environmental mana"ement system audit criteria set

by the or"aniGation are fulfilled.

-.%/ Noncon&or(it0$ ?on$;ulfillment of a re#uirement

-.%2 Pre)enti)e Action$Action to eliminate the cause of a potential

nonconformity

-.%L Procedure$ Specified way to carry out an activity or a process

-.0& Record $ 4ocument statin" results achieved or providin" evidence

of activities performed

he followin" are terms and definitions that have been modified in the

new version of IS' %*&&%)0&&*)


68/98

-.0 Continua' i(+ro)e(ent $ ecurrin" process of enhancin" the

environmental mana"ement system in order to achieve improvements

in overall environmental performance consistent


69/98

of its intentions and principles in relation to its overall environmental

performance which provides a framework for action and for the settin" of

its environmental ob5ectives and tar"etsT

-.%0 En)iron(enta' Tar2et $ 4etailed performance re#uirement

applicable to the or"aniGation or parts there of that arises from the

environmental ob5ectives and that needs to be set and met in order to

achieve those ob5ectives


70/98

of the internal audit has chan"ed from one of determinin" conformance of

the 9:S to determination of conformance with the 9:S audit criteria.

Continua' i(+ro)e(ent $ he definition of continual improvement has

been amended with an additional emphasis that the continual improvement

process is recurrin" and is not a one$off event. he definition also is more

definitive by linkin" it to environmental performance rather than

improvement of the mana"ement system. 'r"aniGations will need to ensure

that they have clearly defined audit criteria.

En)iron(enta' +er&or(ance $ he definition environmental performance

has chan"ed in focus from the mana"ement system to the or"aniGations

mana"ement of its environmental aspects. 'r"aniGations will need to ensure

that the evidence they use to demonstrate environmental performance

improvement is in accordance with the revised definition.

Pre)ention o& +o''ution$ he definition of prevention of pollution has been

clarified to reflect methods and options for the prevention of pollution. An

or"aniGation will need to examine how it defines prevention of pollution


71/98

eflects other environmental re#uirements the or"aniGation may have

subscribed to

Is distributed to everyone workin" for or on behalf of the or"aniGation

such as sub$contractors, contractors, temporary staff, and remote

workers.

. !enera' reuire(ent%

Re)i%ion

his clause of the standard now re#uires the or"aniGation to establish

document implement and maintain an 9:S as previously, but also

continually improve the 9:S and determine how it will fulfill the IS'%*&&% re#uirements. A sentence has been added to the revised standard

which re#uires the or"aniGation to define and document the scope of its

9:S.

I(+'ication

his addition of determine how it will fulfill these re#uirements to

clause *.% re#uires the or"aniGation to state how the 9:S fulfill the

re#uirements of IS' %*&&%. he process will need to be traceable. It

will be insufficient to claim that the internal audit cycle covers all

clauses of the standard and therefore or"aniGation is able to

demonstrate that the 9:S fulfill the re#uirements of IS' %*&&%.

9nsure that the scope of the 9:S is clearly defined and documented

includin" what activitiesM operations, services and products are

included within the scope. ;or or"aniGations seekin" accredited

C'au%e : En)iron(enta' (ana2e(ent %0%te(


72/98

certification, the 9:S scope must a"ree with the re#uirements laid

down by accreditation rules. hese preclude or"aniGations from Xrin"

fencin" their 9:S scope to exclude difficult areas or areas that are

part of their site.

.; En)iron(enta' +o'ic0

Re)i%ion

he environmental policy now must be defined within the scope of the

9:S. he policy must also be communicated to all persons workin" for or

on behalf of the or"aniGation.

he wordin" under policy with re"ard to le"al compliance has chan"ed. he

phrase applicable le"al re#uirements and with other re#uirements to which

the or"aniGation sub$scribes which relate to its environmental aspectsT

replaces the text in IS' %*&&%)%LLH, which referred to relevant

environmental le"islationWT

I(+'ication

o o comply with re#uirement for the environmental policy to be

consistent with the scope of the 9:S the environmental policy must

not cover issues that are wider, narrower or different from that the

9:S scope.

o o demonstrate compliance with the new re#uirements the

environmental policy must)

Be developed by top mana"ement

(over the scope of the 9:S

(over all activities, products and services within the scope of the

9:S

eflect the amended terminolo"y with re"ard to applicable le"al

and other re#uirementsM and


73/98

Be communicated to everyone workin" for or on behalf of the

or"aniGation. his includes contractors, subcontractors,

temporary staff and remote workers.

.?. En)iron(enta' A%+ect%

Re)i%ion:

he or"aniGation is re#uired to establish and maintain a procedure to

identify environmental aspects of its activities, products and services

within the scope of the 9:S.

he re#uirement to take account of the environmental aspects it can

control and over which it can be expected to have an influence has

been chan"e to take account of the environmental aspects it can control

and those that it can influence. Additionally text that used to be in

section on environmental pro"rammes relatin" to planned or new

developments, or new or modified activities, products and servicesT

has been move to the aspects sectionM hence, movin" the re#uirementsto start earlier at the aspect identification state for new pro5ects.

Si"nificant environment aspects must be considered when developin",

implementin" and maintainin" the 9:S, rather than in settin"

environmental ob5ectives as is re#uired in IS' %*&&% ) %LLH.

I(+'ication

Activities, products, or services have been replaced with activities,

products, and services within the scope of the or"aniGations 9:S.

he re#uirement has been chan"ed to those activities, products, and

services that it can influence. his means there is now a clear

re#uirement to determine those aspects that an or"aniGation can

influence in addition to those it can control. he procedure for

identifyin" aspects and impacts needs to be revised to ensure that it


74/98

incorporates activities, products, and services that can be influenced

within the scope of its 9:S.

he aspect identification procedure needs to cover planned or new

developments, or new or modified activities, products and services.

'r"aniGations are re#uired to document the whole process of

identifyin" their environmental aspects and determine which are

si"nificant.

.?.; Le2a' and ot,er reuire(ent%

Re)i%ion:

he first point to note is the "eneral chan"e from the confusin" usa"e

of le"islative, re"ulatory and le"al re#uirements to Xle"al

re#uirements. he world Xle"islative is chan"ed to Xle"al. his

differentiates between Xle"islative, which refers to a law passed by

"overnment, and Xle"al which is much broader and covers re"ulatory,court decisions and others. his does not mean that because a piece of

le"islation is not in the environmental 3rotection Act it is not relevant

to the 9:S.

Amendment has been made to the wordin" on le"al and other

re#uirements


75/98

I(+'ication:

he chan"es in the wordin" of the re#uirement


76/98

representative provide top mana"ement with recommendations for

improvement to the 9:S.

I(+'ication:

he revised clause incorporates resources, roles and authority, in

addition to responsibility, which need to be reflected in the 9:S and

4ocumented procedures.

'r"aniGations are now re#uired to ensure the availabilityT of

resources rather than provideT as was in IS' %*&&%)%LLH. his will

mean. ;or example, that or"aniGation will need to demonstrate that

there are contin"ency plans in place to ensure that competent people

are able to fulfill specific 9:S roles.

..; Co(+etence Trainin2 and A3arene%%

Re)i%ion:

he or"aniGation is re#uired to identify trainin" needs associated with

its environmental aspects and its 9:S and the or"aniGation shallprovide trainin" or take other action to meet establish needs.

'r"aniGations must establish and maintain procedure to make people

performin" tasks for it, or on its behalf, aware of *.*.0 a Q d


77/98


78/98

he decision re"ardin" this matter must be documented by the

or"aniGation. :ost or"aniGations do communicate about their

environmental aspects) sometimes actively to all the public, e.".

throu"h an environmental report or by the use of an environmental

marklo"o on their productM sometimes selectively re#uirements, e.".

monitorin" returns to environmental re"ulators. In all these cases the

or"aniGation will need to establish its methods for communicatin". It

is probable that only very few or"aniGations do not communicate in

some way and hence do not need a method of communication.

.. ocu(entation

Re)i%ion:

his clause has not chan"ed in intent but has been updated to ali"n it more

with IS' L&&%)0&&&.

he listed 9:S documentation now includes the environmental policy,

ob5ectives and tar"ets, a description of the scope of the 9:S, a description

of the main elements of the 9:S and their interaction and reference to

related documents, documents and records re#uired by th

Documents

Alumina Technology