AutomationTechnology for ALUMINIUM

A. RayDirector, NALCO

To be a Company of global repute in Aluminium Sector

VISION

MISSIONTo achieve growth in business with global competitive edge, providing satisfaction tothe customers, employees, shareholders

and community at large.

Incorporated in 1981 as Public Sector under Govt. of India.

Leading manufacturer & exporter of Aluminium in the country.

A five star trading house

An ISO 9002 & ISO 14001 Company

Miniratna status by Govt. of India.

Export of Alumina & Aluminium to about 30 countries.

The total Capital Cost of 24080 MINR was funded through

Govt. of India contribution : 12890 MINR

Euro-dollar loan froma consortium of International Banks : 11190 MINR(Equivalent)

NALCO : LARGEST INTEGRATED ALUMINIUM COMPLEX IN ASIA

LANDMARK EVENTSFoundation-stone laid by Late Smt. Indira Gandhi - March 1981

Commissioning of the Units : September 1985 - March 1987

Commencement of Aluminium Sale - May 1987

Commencement of Alumina Export - Jan. 1988

London Metal Exchange Registration - May 1989

Dedicated to the Nation by Late Shri Rajiv Gandhi - June 1989

Achieved Zero-debt Status - Sept. 1998

Nalco as on Today

Nalco has implemented a major capacity expansion project of 42000MINRfunded mainly through Internal accruals. (Loans - 3000 MINR)

Initial Expanded CommissionedCapacity Capacity

Bauxite 2.4 MTPY 4.8 MTPY Dec’99

Alumina 0.8 MTPY 1.575 MTPY Mar’01

Aluminium 0.230 MTPY 0.345 MTPY Mar’03

Power 720 MW 960 MW Feb’04

Nalco’s expansion plan

• Investment-41000 MINR• Capacity Enhancement-a) Bauxite Mine: 6.3 MTPYb) Alumina : 2.1 MTPY c) Aluminium : 0.46 MTPYd) Power : 1200 MW

AUTOMATION POWER

AUTOMATION REQUIRED FOR

1. Electrical Power systems2. Plant Process systems3. Management Information systems

Present Automation are the state of the art Man –Machine Interfaceand Fiber Optic Network that provides a Real time report on all the key operations

ILMS (Intelligent Load Management Systems)

Load Shedding

TYPES

Fast Load Shedding on Lossof loads Load Shedding on Frequency DropSlow Load Shedding on Overload

Manual Load Shedding

RTU/ Controller

Operator station for Status view and Control

RTU/ Controller

Operator station for Status view and Control

Smelter Substation Control Room

6 K

m s

Generator Inputs/Outputs, Breaker Control

, Breaker Control with Grid Incomer inputs Electrical/

Converter

Electrical/ Converter

ADSS Cable on tower

cpp control room

Status Inputs of the Breaker

2

Hard Copy Laser Jet Printer

Dot Matrix PrinterF

C

E

I

O

A B B T r a n s m i t O yN e t w o r k P a r t n e r

FEEDER TERMINAL REF541A B B N e t w o r k P a r t n e r

U aux = 80...265 Vdc/ac

fn = 50 Hz

In = 1/5 A (I)

1MR S x xx xx x

98150Un = 100/110 V (U)

Uon = 100/110 V (Uo)

Ion = 1/5 A (Io)

950 9

RL

L

R F

C

E

I

O

A B B T r a n s m i t O yN e t w o r k P a r t n e r

FEEDER TERMINAL REF541A B B N e t w o r k P a r t n e r

Uaux = 80...265 Vdc/ac

fn = 50 Hz

In = 1/5 A (I)

1MRS xxxxxx

98150Un = 100/110 V (U)

Uon = 100/110 V (Uo)

Ion = 1/5 A (Io)

950 9

RL

L

R

Line Protection Relays and Islanding Relays

Synchronisation Panel

Example on Typical Load Management System

Engineering Station

GPS receiver for Time sync

Energy Meters

Energy Meters

Energy Meters

.

AUTOMATION FOR RECTIFIERS

Aluminium Smelters demand 100% power round the clock. Transformers and rectifiersmust perform reliably under most arduous anddemanding duty.

1. Use of Industrial Automation in control of rectifiers2. Implementation of Closed loop operation3. Usage of HMI for better understanding4. Interface with SCADA systems for Real time operation5. Better protection during faults

OVERALL SMELTER AUTOMATION SYSTEM

Right from mining of bauxite to casting, Industrial Automation (IA) is the key tosuccess.

Metal Extraction Application Type of Automation

Alumina Measure IADry Scrubber Drive IAAnode Plant Optimize IASwitchyard Protect IADC Conversion Power IASmelter Control IAIngot Skimming Robotics IACasting Operate IA

Automation in Mines

• 16 km single flight cable belt system drive control automation

• Introduction of Auto truck despatch system through GPS

.

Major Automation in Refinery

• Process control of Steam Generation Plant through DCS

• Process Control of refinery plant through DCS

Benefits of Automation– High quality product– Increase in productivity– Safe and Reliable performance of

the system and equipments– Optimisation of resource inputs– Energy Conservation– Environment protection– Increase in life expectancy of

process plant equipments– High over all efficiency of the plant

RESULTS OF AUTOMATION

Issues related to Automation

-Very fast obsolescence-Compatibility

-Standardisation-Cost of Automation