Hindalco Industries Ltd, Hirakud - CII - Sohrabji Godrej Green ...

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Integrity Commitment Passion Seamlessness Speed 1© Confederation of Indian Industry

Hindalco Industries Ltd, Hirakud

Prabhat Kumar Dip – Deputy. Manager(Energy)

Md. Imroz Ahmad – Manager(Technical Cell)

Abhijit Kumar Debata- Dy. Manager (Rectifier Station)


INTRODUCTION TO HINDALCO, HIRAKUD

2

The Hirakud aluminium

smelter, located in

Sambalpur district, is

the oldest operating

smelter in India

Production capacity

increased to 216 KTPA

via brownfield

expansion of GAMI

technology based 235

kA potline, in 2013

Consistent efforts to

uphold sustainability

and consistent value

creation for all

stakeholders

Journey of our smelter

Operations based on old

Soderberg Pot (HSS) technology

Upgraded operations to prebake

technology

Completed brownfield

expansion by addition of 80

pots 1959-05

2006-12

2013-1985 kA

165 kTPA 235 kA216 kTPA

55 kA

10 kTPA

Rated smelting capacity

Operating Amperage

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1a. Sp. Energy Consumption in last 3 years

9.5

1

10.9

0

11.7

5

0

2

4

6

8

10

12

14

FY'17 FY'18 FY'19

Thermal Energy(TOE) FO used in Cast House is high

due to higher quantity of

scrap melting


1b. Sp. Energy Consumption in last 3 years

14

,83

9

14

,72

3

14

,89

1

14

,76

7

14600

14650

14700

14750

14800

14850

14900

14950

FY'17 FY'18 FY'19 FY'19 after

normalisation

DC Specific Energy KWH/MT 66 nos pots failed

due to flooding in

July-2018

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1c. Sp. Energy Consumption in last 3 years4

.57

4.4

4

4.4

7

4.4

6

4.35

4.4

4.45

4.5

4.55

4.6

FY-16 FY-17 FY-18 FY'19

AC SEC (TOE/MT)

AC SEC (TOE/MT)

Linear (AC SEC (TOE/MT))

Specific Energy as per

Form-1


National & Global benchmark

56

.30

55.8

6

56

.51

52.4

1

48

.81

FY-17 FY-18 FY-19 Indian Benchmark Global Benchmark

AC SEC(GJ/MT)

Source : CII https://www.keralaenergy.gov.in/files/Resources/Aluminium_Sector_2018.pdf

However we have

no reference of low

kA old technology

Smelter Worldwide

https://www.keralaenergy.gov.in/files/Resources/Aluminium_Sector_2018.pdf

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3a. Energy Saving projects implemented in FY ‘17

DescriptionSl. No Savings

Use of new design copper inserted collector bar to save 70 mv/pot(72pots/yr) 1 260610 KWH

Cathode lining optimization to reduce 25 mv / pot(72pots/yr) 2 1340280 KWH

Install FTP fan with VFD in FTP 13 2190000 KWH

Energy reduction in Anode Assembly (Yoke to Carbon Drop) and design

change of depth of stub hole to reduce 10 mv/pot 4 1608336 KWH


3b. Energy Saving projects implemented in FY ‘18


Use of new design copper inserted collector bar to save 70 mv/pot(72pots/yr) 1 1563660 KWH

Cathode lining optimization to reduce 25 mv / pot(72pots/yr) 2 1340280 KWH

Replacement of RS-III CT cold well pumps with Energy Efficient Pumps3 350400 KWH

Energy reduction in Anode Assembly (Yoke to Carbon Drop) and design

change of depth of stub hole to reduce 10 mv/pot 4 3909150 KWH

Current density equalization by anode change for saving 20 mv/pot5 7818300 KWH

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3c. Energy Saving projects implemented in FY 2018-19


Magnetic Compensation Bus bar Implementation 1 1298512 KWH

Anode stub hole modification in Rodding plant2 101353 KWH

Installation of 25MVAR Harmonic Filter (132KV ) at Rectifier station-43 1027898 KWH

100 % CI Rodding through Aditya CSS IN 235kA5 5072390 KWH

Use of new design copper inserted collector bar to save 70 mv/pot 4 5457480 KWH


Summary of Energy Saving Projects(FY16-FY19)

Year No.of Proposal Investments Savings Payback years

2016-17 4 1800000 20409074.3 1.058352755

2017-18 5 20900000 64721332.8 3.875074711

2018-19 5 13710000 57013585.2 2.885628038

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OVERVIEW

Cross-sectional schematic diagram of CellTop view of a potline

(in series)

Energy - the largest cost component

High SEC(14200kWh/mt) compare to

modern technology Plant

Low CE-93.2%

11

Rectifier

Room

-A

Room

-B

Cu

rrent o

ut

Cu

rrent in

Cathode Cathode

Anode rod

Al2O3+C 13-15kwh/kg Al+CO2


CHALLENGES ENCOUNTERED

12

Hot spots Sludge and muck

Designed for 1,800 days

Started failing early

Poor flow profile

Poor alumina distribution

Resulting in

GAMI (technology supplier) also tried operating the pot for a year but failed

Sludge & MuckLoss in production man-days

High energy consumption

Difficulties in pot operation

i. Poor metal flow profile

ii. High peripheral temperature

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Magnetic field measurementAnode current distributionSuperheat measurement

MEASUREMENT AND ANALYSIS

13

Joint venture of Hirakud &

JNARDDC Continuous measurement is in

progress in both the potlines

since December, 2018

Quick actions for controlling

bath chemistry

Joint venture of Hirakud &

Maesteria

To improve CV and standard

deviation of ACD

To achieve 0.5% gain in

current efficiency

Hirakud & ABSTC

To measure magnitude and

direction of magnetic field at

different location

To see actual impact of design

and simulation


MEASUREMENT AND ANALYSIS

Ledge profile measurement Thermal image steel shell

Key challenges were evaluated through the below analysis

Metal velocity measurement

The above methods aided in identifying the shortcomings in design

14

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Gap Analysis (Design vs actual)

15

Discovered an underlying energy saving potential of ~600kWh/T

0.380 V 0.400 VAnode Voltage

1.545 + 1.850 V 1.560 + 1.850 VElectrolyte Voltage

0.250 V 0.320 VCathode Voltage

0.240 V 0.240 VFixed Voltage

4.265 V 4.37 VTotal Voltage

13,600 kWh/T 14,200 kWh/TSpecific energy

GAMI - Specification Actual

Cathode

Insulation and refractories

Metal

(+)

Current in

Riser

Anode beam

Anode rod

Anode cover

(-)(-)

Cathode beam

Current Out Current Out

Collector bars

Anode


Project No:1 MAGNETIC COMPENSATION

Modelling and simulation

Magnetic field, metal velocity

16

Rectifier

&

Transformer

In

Out

Potline

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MAGNETIC COMPENSATION (Contd.)

17

Velocity profile

Average velocity reduced from 5.1 to 4.8 cm/s

Maximum velocity reduced from 20 to 12 cm/s

Eliminated dead zone at centerPlant challenges!


Key milestones

MAGNETIC COMPENSATION (Contd.)

18

Executed project in 5 months (in-house)

Ensured 100% safety compliance

Extended measurement of pots to avoid any incident

Validated model predictions

First time in India and first in co-current in the

world, patent filing under progress.

Current efficiency gain of 0.5%.

Welding job under -2.5 level

Placement of busbarBusbar transfer from

warehouse

Energy saving of 170 kWh/T in the entire plant

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PROJECT2:ANODE DESIGN MODIFICATION

19

Voltage used to drop to ~30% of total anode voltage

The pin to carbon voltage was reduced by increasing the pin diameter while

keeping the pin hole diameter unchanged

Increased the contact pressure between pin and carbon, reducing the voltage

drop.

Energy saving of 100 kWh/T

Pin to carbon voltage reduction

132

100

50

60

70

80

90

100

110

120

130

140

Hirakud (before

modification)

Hirakud (after

modification)

Volt

age d

rop

(m

V)

Pin diameter increased by 10 mm

150160160 160


Project No: 3 132kV Harmonic Filter

Objective: To improve the power factor from 0.945 to 0.995 & reduce

generator VAR generation.

Rectifier sub-station - 4 is equipped with 2 Nos of harmonic filters of total capacity 37.22

MVAR and present power factor is 0.945 lagging. Therefore it was clear that there is a scope

of further improvement of power factor by installing an additional bank till 0.995 lagging or

better. Additional reactive load requirement is estimated to be 25 MVAR to achieve the

desired power factor.

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Harmonic Filter Cont.

❖Harmonic Spectrum Consider as below.

Bank-1 Bank-2

Tuning 4.08 10.40

Frequency(Hz) 204 520

Generation (MVAr) 10 15

Proposed Filter Bank.

.132kV,10MVAr,BP Harmonic Filter bank.

132kV,15MVAr,BP Harmonic Filter bank

THDV is with-in IEEE limits with the above proposed filter banks along with the existing 5th & 11th

harmonic filter bank subject to the harmonics considered in the design basis and with min fault MVA of

5000 MVA and max of 9200 MVA with frequency variation of +/- 5%.


Tangible Benefits

INPUT SECTION

❖Maximum Load(kW) 89000

❖Existing P.F. 0.945

❖Desired P.F. 0.995

❖Operating Voltage 132000

OUTPUT SECTION

❖kVA of Existing P.F. 92037

❖kVA at improved P.F. 89447

❖Saving in (kVA) 2590

❖KVAr at existing P.F.(KVAr) 28448

❖KVAr at improved P.F(KVAr) 3448

❖KVAr required(KVAr) 25000

❖Load current at existing P.F(Amp) 403

❖Load current at improved P.F(Amp) 391

❖Reduction in load current (Amp) 12

❖Additional benefit is relief of 2.59 MVA in apparent power on TG in normal operation and in demand when

operating on Grid supply. Also there will be reduction in energy consumption of cooling system of the

generator.

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14,282

13,850

13600

13,500

13,900

14,300

14,700

Ap

r'18

Ma

y'1

8

Ju

n'1

8

Ju

l'18

Au

g'1

8

Sep

'18

Oct'

18

No

v'1

8

Dec'1

8

Jan

'19

Feb

'19

Ma

r'1

9

Ap

r'19

Au

g'1

9

Fy

'20

Fy

'21

Actual P&B Projected

IMPACT - ENERGY SAVINGS(235kA)

23

14,282

13,742

170

210

60 100

FY'18 Energy External busbar CuCB * Cathode sealing Anode drop Energy FY'20

Project/Area Energy saving potential (kWh/T)

Magnetic

compensation loop 170

Cathode voltage

reduction 210

Anode Voltage

reduction 100

Current

Efficiency

Increase by 0.5%;

production will increase by

270MT/year

Energy Reduction through projects

Yearly energy trend (kWh/T)

* Copper inserted collector bar

Energy savings break-up (kWh/T)


IMPACT - COST SAVINGS(235kA)

24

Project/Area Investment

(in Cr.)

Maximum potential for financial

gain (Cr. per annum)

Realized financial gain

(in Cr.) @ Rs. 4/unit

Magnetic

compensation loop 4.00 3.35 1.67 (for 6 months)

Cathode voltage reduction 11.7 4.26

1.88 (will increase

after full potline

conversion)

Anode Voltage reduction 1.30 2.03 1.70 (for 10 months)

Harmonic filter 2.27 0.45 0.45

Current Efficiency NA Cost savings of Rs. 3.39 Cr. /year

Total annual savings potential of Rs. 15 Cr.

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In house

development

Process control

initiatives –

JNARDDC,

MAESTERIA,

ROCKWELL

Concept

replication

from peers

First in India

initiatives through

ABSTC

COLLABORATI

ON &

SEAMLESSNES

S

SUSTAINABLE WAY FORWARD

25

Copper inserted collector bar replicated at Aditya & Mahan unit

Renukoot plant is planning to Implement compensating busbar (sustainable solution for any old potline without hampering production)

External busbar concept implemented in 6 pots of 85kA potline after completion, energy will be 13400kWh/MT

Anode stub modification in-house developed through DOE initiative

Forced cooling is a sustainable solution for any high kA GAMI potline

Technical knowledge of the team has increased; motivated to carry out other sustainable energy reduction projects

Increased collaboration across all Hindalco plants & ABSTC


2018 -2020

Commissioning

2013 -15

Developmental

zone

Energy Consumption

DC-kWh/ton

SUSTAINABLE WAY FORWARD (Contd.)

26

Changes call for innovation and innovation leads to progress

VISION 2022

Achieve

14,250

2022 onwards

13,750

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Established in the year1958 and with continuous capacity enhancement in limited

space, therefore no major actions could be taken on Renewable Energy Sources

except partially installed solar light. However we purchase REC’s as a part of RPO

obligations

5. Utilisation of renewable energy sources


6. Utilisation of waste material as fuel

Pro

ject

1

Uses of waste wood for bath recovery in calciner

Pro

ject

2

Uses of used carbon anode butt for metal recovery from Dross(First time in India).

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7. GHG20.3

6

19.8

20.6

3

FY-17 FY-18 FY'19

GHG (tCO2/t)

Target is to reduce by 35% taking 2005 as base.

The figures of Hindalco is disclosed in the yearly

sustainability report

30

,92

,70

4

32

,06

,27

3

34

,39

,39

2

FY-17 FY-18 FY'19

GHG Absolute tCO2

1. considered Scope-1 and Scope-2,

addition of Scope-3 is in process

GHG increased due to

flooding in July’2019

where we lost 66 pots


8. Green Supply Chain

Alumina used in the process is transported by rakes.

Anodes used in the process is purchased from Adityawhich was earlier imported from China.

No loading/unloading vehicle is entered in the plant premises without valid pollution certificate.

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1.We monitor SEC in terms of ACE,DC, Conversion Loss,FTP & Auxillary on daily basis.

2.Review meeting chaired by Mr.J.P. Nayak(Smelter Head) monthly.

3 Separate budget for Energy Conservation via Galaxy projects

4. Energy efficiency / awareness training program at Business, Cluster as well as Plant Level

organised by Corporate Energy cell and Plant Energy cell.

5. Projects are being implemented through Kaizens ( Workers and Supervisor level)

• Timer control of Plant Lighting

• Occupancy Sensor for offices.

9. Team work, Employee Involvement & Monitoring


Daily Energy Monitoring

ABSOLUTE ENERGY (KWH) Potline

Average Dc

Voltage in

Volts

Potline

Average DC

Current in

kA

Metal

Production

in KGAC EnergyAC For

ElectrolysisDC Energy

Conversion

lossFTP Energy

Total

AuxiliaryCast House

Total aux

excluding

cast house

SPECIFIC ENERGY (KWH/MT)

AC Energy AC For Electrolysis DC Energy Conversion loss FTP Energy Total AuxiliaryTotal Auxiliary

excluding CH

We monitor the absolute as well as the specific energy consumption daily &

monthly for all the potlines as well as total plant.

Cast House Daily MIS Format

Date

Productio

n(T)

FRP

scrap(T)

Process

scrap(T)

Hot

metal(T) FO Consumption(KL)

Solid Ratio

(%)

Sp fuel

consumption(L/T) Remarks

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We are ISO 50001:2011 certified organization

10. Implementation of ISO 50001/Green Co/IGBC rating

We are certified with ISO50001:2011.

Outcomes of Stage 2 Audit.

1. Luxmeter was not calibrated

2. All Cast Houses not included in SEU’s.

3. EOT crane not considered as SEU.

4. Strengthening Lighting Control

% Investment on turnover FY’19 – 0.1658 %


11. Other Innovative Technology

AlF3 prediction model with the help of AI is being tested in one pot and is in

progress.

Electronic Pot Controller is being

replaced with PLC’s

MES Digitalization of plant data for AI

through Aspen –Tech

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12. Long term vision on EE

PLC based pot controllers have been installed which will give us flexibility in process change

Coal gasification project is under progress which will be used instead of FO in Cast Houses

Graphitized cathode block to reduce DC energy


THANK YOU

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