Aluminium Business1
19th National Award for Excellence in Energy Management – 2018
Asia’s 1st ISO-50001 certified Smelter
Team Members:
Bibhudatta Mohanty – Associate General ManagerManoj Senapati – Associate ManagerDilip Kumar Satpathy – Associate Manager
Aluminium Business2
Core Purpose “Vedanta is a globally diversified natural
resources company with low cost
operations. We empower our people to
drive excellence and innovation to create
value for our stakeholders. We
demonstrate world-class standards of
governance, safety, sustainability & social
responsibility”
PURPOSE & VALUES
Vedanta Core
Values
Trust
Entrepreneur-ship
Innovation
ExcellenceIntegrity
Respect
Care
Aluminium Business3
5 LTPA Aluminium Smelter 1215 MW CPP
12.5 LTPA Aluminium Smelter 2400 MW IPP
VEDANTA LIMITED, JHARSUGUDA
Aluminium Business5
❖ Pot Room:
➢ GP – 320 Prebake Technology
➢ No. of lines – 2
➢ No. of pots in each line – 304
➢ Pot amperage – 328 kA
➢ Design Capacity – 0.5 MTPA
❖ Carbon:
➢ GAP – 2 Paste plants
➢ Bake Oven – 4 Bake furnaces.
➢ Anode Rodding Plant
❖ Cast House
➢ Ingot Casting Mill – 3 Lines
➢ Wire Rod Mill – 2 Lines
➢ Billet Casting Line – 1 Line
SMELTER – 1
Conserve energy to preserve natural resources.
Aluminium Business6
Ingot Casting Machine
Technology• BEFASA, Spain
Plant Capacity• 450 KTPA
Product DestinationApar Industries Ltd. Jindal Aluminium Limited.STX, Daechang, Dreample (Korea)Southern Aluminum (China), etc
Slab Casting Machine
Technology• WAGSTAFF, USA
Plant Capacity• 100 KTPA
Product DestinationNovelis(Korea)Garmco(Middle East)Hindalco, etc
Wire Rod Mill
Technology• SOUTHWIRE, USA• Properzi, Italy.
Plant Capacity • 120 KTPA
Product DestinationPolycab Wires Pvt. Ltd.Havell's India LtdNepal Wires (Nepal)Etsec (Kenya), etc
Billet Casting Machine
Technology• WAGSTAFF, USA
Plant Capacity• 120 KTPA
Product DestinationCentury Extrusions LimitedAlom Extrusions Limited (Turkey)Hyundai Aluminum (Vietnam)Wespeco (South Africa), etc
PRODUCT MIX
Aluminium Business7
ALUMINIUM - ENERGY & COST
36%
64%
Energy Cost Other Cost
98%
2%
Electricity
Fuel
DC Energy
95%
Auxillary Energy5%
DC Energy consumption = 2.98*Volts/pot
Current Efficiency
Focus is on DC energy reduction
Conservation: It doesn't cost. It saves
Aluminium Business8
SPECIFIC ENERGY CONSUMPTION TRENDS
“Fruitful result of our efforts”
SPECIFIC AC CONSUMPTION (kWh/MT)
13939
13877
13862
1349313466
13400
13600
13800
14000
2015-16 2016-17 2017-18 Q1 2018-19 Target 2018-19
1370013643.25
13638
1329113258
12900
13000
13100
13200
13300
13400
13500
13600
13700
13800
2015-16 2016-17 2017-18 Q1 2018-19 Target
SPECIFIC DC ENERGY CONSUMPTION(KWH/MT)
SPECIFIC DC ENERGY
CONSUMPTION(KWH/MT)
SPECIFIC AC
CONSUMPTION(KWH/MT)
Aluminium Business9
PERFORMANCE BENCHMARKING
13817
1350013528
13405
13301
13000
13100
13200
13300
13400
13500
13600
13700
13800
13900
A B JSG-P2 JSG-P1 Balco
Kw
h/M
T
Indian Aluminium Companies
DC Power (Kwh/MT)
One measurement is worth a thousand expert opinions
Aluminium Business10
ENCON PROJECTS (Last 3 Yrs)
Zero investment projects
Investment Projects
“Small Investments, High Returns”
CategoryNo of ENCON
projectsEnergy Savings Energy Savings
Saving in Million Rs.(MkWh) (MKcal of fuel)
DC - - - -
Auxiliary 77 12.62 - 33.05
Fuel - - - -Total 77 12.62 - 33.05
Category
No of ENCON projects
Energy Savings (MkWh)
Energy SavingsSaving in Million Rs. Investment in
Million Rs.(MKcal of fuel)
DC 5 45.18 - 139.97 580.93
Auxiliary 21 2.16 - 6.97 14.14
Fuel 1 - 17062 61 15Total 27 47.34 17062 207.94 610.07
Aluminium Business11
S.No. Title of Project
Annual energy
Saving,
Million kWh
Total Annual
Savings,
Million Rs
Investment
Made (Rs
million)
Payback
1 HP power optimization 4.99 12.53 0.00 0.00
2 Stoppage of bulk tank storage heaters in Bake Oven 0.24 0.59 0.00 0.00
3 FTA low vacuum unit run time optimisation 0.19 0.48 0.00 0.00
4 Lighting Energy optimisation in Rectifier 0.11 0.29 0.00 0.00
5Cooling Ramp shutdown Before fire change for 5
Hours0.11 0.26 0.00 0.00
6 Automation of cooling tower 0.09 0.22 0.00 0.00
7Running Hour optimisation of R Group Pumps in
GAP0.09 0.22 0.00 0.00
8 LP compressor tuning 0.09 0.22 0.00 0.00
9 Use of Cold sealing paste in pot relining 0.09 0.22 0.44 24.00
10 Timerbased valve in dryer 0.09 0.22 0.00 0.00
11 VFD installation in DRC id fan 0.08 0.21 0.25 15.00
12LCP room partition there by saving AC running time
and hence energy0.07 0.16 0.00 0.00
13Grouping system hydraulic power pack runtime
optimization0.06 0.16 0.00 0.00
14Decrement in Idle running of Hydraulic Pump in
Cast House0.06 0.16 0.00 0.00
15 Bypassing of filter pump motor 0.06 0.14 0.00 0.00
ENCON PROJECTS FY 2015-16
Total energy savings for FY 2015-16 = 6.9 Million Kwh
Aluminium Business12
ENCON PROJECTS FY 2016-17
S.No. Title of Project
Annual Energy
Saving,
Million kWh
Total Annual
Savings,
Million Rs
Investment
Made (Rs
million)
Payback
1 Dead Pot reduction 13.84 35.99 12.60 4.00
2Improvement in rectifier conversion efficiency
by 0.04%2.31 6.01 0.00 0.00
3Reduction in Heater Tripping by DMAIC
methodology0.80 2.08 0.00 0.00
4 ETP power optimization 0.35 0.91 0.00 0.00
5 Sniff panel modification 0.15 0.38 0.00 0.00
6 CMW lighting load segregation 0.15 0.38 0.00 0.00
7 Rectifier unit LCP room AC optimization 0.14 0.36 0.00 0.00
8 Pump coating 0.12 0.32 0.00 0.00
9 Air slide fan running hour optimization 0.11 0.27 0.00 0.00
10 Auto Stop CWP5 after Billet casting cool down 0.10 0.27 0.00 0.00
11 New cooling tower running hour optimization 0.10 0.25 0.00 0.00
12Heating ramp heater temperature set point
optimization0.09 0.24 0.00 0.00
13 LED lights intallation 0.08 0.20 0.98 60.00
14 Eliminate Idle Running of F330 & F335 SC 0.06 0.16 0.00 0.00
15 Day tank heater Set point Optimization 0.06 0.15 0.00 0.00
Total energy savings for FY 2016-17 = 18.87 Million Kwh
Aluminium Business13
ENCON PROJECTS FY 2017-18
S.No. Title of Project
Annual Energy
Saving,
Million kWh
Total Annual
Savings,
Million Rs
Investment
Made (Rs
million)
Payback
1 SGL100% cathode implementation 25.34 84.12 516.60 74.00
2 SHANDONG cathode implementation 5.91 19.61 51.28 31.00
3 FTP air slide fan optimization 0.65 2.15 0.00 0.00
4 VFD installation for new pump house 0.53 1.74 0.60 4.00
5 Pump coating 0.53 1.74 0.10 1.00
6
Replacement of existing lights with LED lights
in plant street light, office, MCC and shopfloor
areas
0.42 1.40 5.44 46.00
7 Cooling tower running optimizaion 0.26 0.87 0.00 0.00
8 Installation of energy efficient Air conditioner 0.11 0.37 3.47 113.00
9 Lighting Automation in different areas of plant 0.09 0.29 0.03 1.00
10CWP 4 Drive installation and to be run in 80%
capacity mode.0.09 0.29 0.31 13.00
11CT1 Drive installation and to be run in
temperature feedback control mode0.08 0.25 0.07 3.00
12Optimization of run time Grouping Hydraulic
motor by removal of lift shift operation0.07 0.22 0.00 0.00
13 Daytank heater set point optimisation . 0.06 0.20 0.00 0.00
14vacuum unit idle time reduce from 10 minutes
to 5 minutes.0.05 0.16 0.00 0.00
15 WCS cooling fan run time optimization 0.04 0.12 0.00 0.00
Total energy savings for FY 2017-18 = 34.22 Million Kwh
Aluminium Business14
MAJOR ENERGY SAVING PROJECTS
(FY 2017-18)
Sl.No Project descriptionEnergy saving in MkWh/Annum
1 SGL100% cathode implementation 25.34
2 SHANDONG cathode implementation 5.91
3 FTP air slide fan optimization 0.65
Spare a Watt; Save a Lot
Aluminium Business15
SGL100% CATHODE
Existing 50% graphitized cathodes are replaced with 100% graphitized cathodes.
Benefits of implementation:• Resistivity reduced from 26 ohm-cm to 12 ohm-cm.• Operating Voltage decrease from 4.182V to 4.126V• CVD (Cathode voltage drop) decreased to 247mV from 385mV• Which resulting a huge energy saving by the reduction of Specific DC energy consumption from
13369Kwh/Mt to 12874Kwh/Mt.
Energy saved is energy produced
Energy Conservation: 25.34 MkWh/ Annum
12400
12800
13200
13600
14000
92
93
94
95
96
30% Graphized Block 50% Graphized Block 100% Graphized Block
Kwh
/MT
%
Cathode Modification Journey
CE(%) DC Power (Kwh/MT)
Aluminium Business16
FTP AIR SLIDE FAN OPTIMIZATION
Power saved is power produced
FTP is being operated with 2 airslide fans for conveying alumina in airslides. Airslide fan is being operated by a
55 KW motor which is running at 40% load for 24 hours a day. By switching off one air slide fan and operating
other at 60% load huge amount of energy is saved without disturbing environment by HF emission.
Energy Conservation: 0.65 MkWh/ Annum
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.45
1-Jun-17 8-Jun-17 15-Jun-17 22-Jun-17 29-Jun-17 6-Jul-17 13-Jul-17 20-Jul-17 27-Jul-17
FTP HF Emission Trend
FTP-2 Target
Aluminium Business17
INNOVATIVE PROJECTS IMPLEMENTED
Before:
Volume of air consumed in
one cooling point = Volume
of air consumed in 1 inch
hose = 2.8 m3/min = 0.014
MW per day
After:
Volume of air consumed in
one cooling point = Volume of
air consumed in 1/4 inch
hose by nozzle = 0.22
m3/min = 0.001 MW per day
Nozzle & Cooling fin POT cooling
Energy saving = 13KW per day
Aluminium Business18
Conversion of existing lights to LED
Energy Conservation: 0.42 MkWh
• For better illumination and energy saving, existing lights are replaced with LED in office, MCC room, Control
room, shop floor, street lights etc.
• Around 2000 nos. of existing lights of wattage (32W, 36W, 250W & 400W) were replaced with LED of lower
wattage(18W, 120W, 150W & 200W).
• 100% LED conversion by 2020.
INNOVATIVE PROJECTS IMPLEMENTED
Aluminium Business19
VFD for new pump house
2 no's of 110 KW VFDs are installed in
two pumps, we observe energy saving
30kW/pump.
Energy Conservation: 0.53 MkWh
Around 70 no’s of split AC replaced with
energy efficient Air conditioner in
different location of Plant.
Energy Conservation: 0.11 MkWh
Energy Efficient Air conditioner
INNOVATIVE PROJECTS IMPLEMENTED
Aluminium Business20
VFD installation in Cast house cooling tower-1
Repaired Drive installed in cast house cooling tower-1
which leads to save energy upto 8KW per day.
Temperature RTD installation in cold well sink to get
the temperature feedback of cold well. Based on the
closed loop feed back the CT runs
Energy Conservation: 0.08 MkWh
INNOVATIVE PROJECTS IMPLEMENTED
Aluminium Business21 It’s Your World. Take Control
10KW SOLAR SYSTEM
Energy Conservation: 0.0015 MkWh
SOLAR WATER EVAPORATOR
Energy Saving 5000 Units/Annum
Planning of commissioning around 200KW solar power system in the near future.
RENEWABLE ENERGY SOURCES
Aluminium Business22
Sl No. Initiatives Taken
1 Co-Incineration of Contaminated Carbon Dust and Anode Butts in CPP
2 Incineration of used Bag Filters in Baking Furnaces
3 Regulated consumption of Contaminated Alumina
4 Recycling of waste of Ramming Paste in Carbon Plant
5 Recycling of broken Cathodes in Carbon Plant
6 Recycling of Refractory Waste
7 Recycling of used steel stub pins in cast iron
8 Recycling of used steel collector bars
9 Recycling of effluent water for gardening
10 Rejected Anode butt utilization
UTILISATION OF WASTE
“Whatever Half Full or Half Empty, Resources are limited”
Aluminium Business23
Efforts towards GHG emission reduction :
▪ GHG calculation done by M/s KPMG.
▪ Shuttle service started to optimize light vehicle movement.
▪ 100% Alumina transportation through rail traffic.
▪ 100% Finished goods transportation by rake.
CARBON FOOT PRINT ACTIVITIES
Let's Cut Carbs...Our Carbon footprint, that is
YearScope 1 emissions
CO2e (MT)Scope 2 emissions
CO2e (MT)Scope 3 emissions
CO2e (MT)CO2e MT
MitigationTotal Reduction in emission intensity since baseline year study CO2e (MT)
2014 - 15 8673537 1,697 323,278 8,998,512 Baseline Year
2015 - 16 10568356 8,403 321,478 10,897,237 -1,898,725
2016- 17 15098803 45,942 399,815 15,544,560 -6,546,048
2017- 18 19827752 76,404 738,042 20,642,198 -11,643,686
Aluminium Business24
CARBON FOOT PRINT ACTIVITIES
Reduction in specific HFO consumption
43.5
44
44.5
45
45.5
46
46.5
47
47.5
FY' 16-17 FY'17-18 FY' 18-19 (Target)
47.13
46.08
44.98
Improvement Actions Taken:➢ Optimization of pulsing oil injection in heating ramp. i.e, Firing of oil started after 8 hours of fire changeover maintaining CRR of
92%.➢ Peep hole modification done by putting ceramic coating cloth in it by reducing top surface temperature from 346 degree Celsius to
185 degree Celsius.➢ Gap between burner stand & ring is covered with packing coke.
Way forward:➢ Firing system level-2 SCADA up gradation for monitoring of flooding index of HFO and CO2.➢ Provision of flow meter in each ramp for better monitoring of HFO consumption.
Gap between burner stand & ring
Gap covered with packing coke
No covering around burner base
Covered with coke around burner base
Aluminium Business25
CARBON FOOT PRINT ACTIVITIES
Reduction in Specific Diesel consumption
2.7
2.72
2.74
2.76
2.78
2.8
2.82
2.84
2.86
FY'16-17 FY'17-18 FY'18-19(Target)
2.85
2.81
2.72
Improvement Actions Taken:➢ To optimize the idle running of engines in full RPM at the time of seal changing and pressure making in workshop, external compressor
unit installed to perform the pneumatic related operations in metal tapping vehicles.➢ Shortest path identification for process vehicles movement in plant premises.
Way forward:➢ Software up gradation in 2 MTVs by changing the controller and related programming so as to get the fuel savings like MTV 15
Aluminium Business26
CARBON FOOT PRINT ACTIVITIES
Reprocessing of Spent Pot Lining (SPL)
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
2015-16 2016-17 2017-18
684.24 1003.54
9005.5
Quantity of SPL(MT)
Way forward :
Tie-up with Green Energy Reprocessor for evacuating 4,200 MT per month with a vision of evacuating
entire SPL from our site in a time span of 18 months.
Aluminium Business27
E-DMS DOCUMENT CONTROL & APPROVAL
ENERGY EFFICIENT PROCUREMENT
DIGITISATION OF EnMS
E-CER (CAPEX PROJECT) ENERGY IMPACT ASSESSMENT
MES ONLINE FLASH REPORT
“Automation leads to Perfection”
Aluminium Business28
ENERGY MONITORING & REPORTS
SEC Report to Plant Head
Section Wise Report to Energy Managers
Daily reports to HODs
Energy Management SCADA
Parameters & Monitoring Frequency
High Energy Consumers Daily
Fuel Consumption Daily
Compressed Air Consumption Daily
Water Consumption Daily
“Monitor to Control”
Aluminium Business29
Non-Conformity Statement :
➢ In significant activity sheet maintenancerelated activities which impact to theenergy performance was notmentioned.
Corrective Actions Done :
➢ Significant activity sheet prepared forthose maintenance activity which isimpacting energy consumption.
IMPLEMENTATION OF CORRECTIVE /
PREVENTIVE ACTIONS
Aluminium Business30
Flow measurement
Major Energy Consumers
• Integrated Energy Meters are installed in the Sub Stations
• Related Process parameter are displayed on the screen
• Data is captured from these resources at regular intervals
Other Energy Consumers
• Energy consumption is measured by Power Analyzers before & after the Project for quantification of savings
• Flow measurements are taken for quantification of savings before & after the project
• Fuel consumptions are validated by third party auditors every month
• Meters used for all measurements are calibrated as per ISO Standards
“Well defined measurement system to quantify & validate ”
Energy measurement
Integrated Energy Meters
Flow measurement
ENERGY MONITORING & QUANTIFICATION
Aluminium Business31
ENERGY CONSERVATION WITH TQM
“Improvement is an Infection”
2016-17 NOS.
SAVING
INVESTMENT (Rs. In Million)
NOS. OF PEOPLE INVOVEDPOWER
(Million Units/Annum)COST
(Rs.in Million)
SIX SIGMA 1 0.65 2.15 0 12
QC 2 0.64 2.11 4.07 10
KAIZEN 17 2.85 5.62 7.955 to 6 members in each
project
Conserve to Preserve
Aluminium Business32
PEOPLE INVOLVEMENT
Energy Dash board on Shop floorEnergy discussion in daily War-room
Energy awareness in Tool Box Talk.Awards & Recognition for Energy
initiatives
“We value every small contribution”
Aluminium Business34
Energy Policy
Energy Review
EnPI
&
Sub- EnPI
Opportunity List
Objective, Targets &
Action Plan
Monitoring, Measurement
Analysis & Review
Energy Audit , Corrective &
Preventive action
ENERGY MANAGEMENT SYSTEM
(ISO-50001)
1st Smelter in Asia ISO-50001 certified
Aluminium Business35
REVIEW STRUCTURE
Formation of Energy Cell
SBU level energy review
Review by Energy Manager
Management review by Plant
Head
Monthly operation review
by Head Aluminium operations
Corporate Sustainability
review
APEX Committee
CORE Committee
COORDINATING
CommitteeSGA Team
“Bottom to Top Approach”
Aluminium Business36
ENERGY POLICY & OBJECTIVES(2018-2019)
ENMS OBJECTIVES
▪ Reduce DC Energy Consumption▪ Reduce Auxiliary Energy Consumption ▪ Reduce HFO Consumption ▪ Reduce Diesel Consumption
Aluminium Business37
Air Pollution Management
• De-dusting units along with bag filters
• Introduction of Electro Static Precipitator (ESP)
• Installation of CAAQMS for continuous air quality monitoring
Water Pollution
Management
• Online waste water monitoring system
• Storm water guard pond
UF & RO PlantReal time monitoring of ambient air
ENVIRONMENTAL PROJECTS & INITIATIVES
Every action has a reaction
Aluminium Business38
Waste Management
• Segregation biodegradable & non biodegradablewaste
• High Concentration Slurry Disposal (HCSD) -1st In Odisha
Hazardous Waste
Management
• Secured Landfill
• Use Of Incinerator (Fluorinated Waste)
Hazardous Waste Incinerator
Hazardous Waste LandfillHigh Concentration Slurry Disposal
ENVIRONMENTAL PROJECTS & INITIATIVES
Earth: Cherish or perish.
Biomedical Deep burial pit
Color coding for diff. types of waste
Aluminium Business39
Water Conservation▪ Treatment and recycling of effluent water▪Principle of “Zero” effluent water discharge▪Upgrading ETP with Ultra-filtration & Reverse Osmosis for maximum water recycling.▪Storm water guard pond for management of storm water.▪Installation of robust quality of float vales to avoid overflow of water from sintex tank.▪Recycling of Ash pond water for using in ash handling plant
Rain Water Harvesting• A study on Rain Water Harvesting has been
conducted by Andhra University and the report has been submitted to CGWA / OSPCB for their technical suggestion.
• Approval received from CGWA.
ENVIRONMENTAL PROJECTS & INITIATIVES
“Every drop counts”
Aluminium Business40
“Each one Plant one” taken on world Environment Day in which all employees & contractors have planted one tree across the location
Environment Incident Management System
Waste Management Systems under Sustainability Framework
Rehabilitation of Ash filled area by plantation
Green Jharsuguda Project – in PPP mode 100750 saplings at Behrapat, Lohrabudh & Banjari village
INITIATIVES FOR A GREENER TOMORROW
“Fulfilling our dream of Clean & Green India”
Aluminium Business41
ENCON EFFORTS –A NOTCH UP
Energy Audit by CII
Energy Audit by TERI
EnMS Implemented
ISO 50001 Certified ENCON award from BEE and CII
ENCON award from BEE , CII & GMEA
Russian Gov. Award-Best Energy Efficient project realized abroad
FICCI audit, M&V audit-PAT
NECA -2nd Prize
Energy Management Insight award
PAT cycle-1 best achiever award SEEM award
2010
2011
2014
2012
2015
2013
2016
2017
Clamp Drop
Fuse Technology
Slotted Anode
Cathode &
HFO
HFO & Conversion Efficiency
Technology up gradation in potline
Aluminium Business42
ENCON PROJECTS
(Ongoing/Upcoming)
“Our plans for a better Tomorrow”
Sl.no Title of Project YearEstimated Annual
Savings, MkWh
1 Revamping of homogenising furnace and up gradation of insulation 2018-19 3.577
2Pot controller and lining design up gradation to improve specific DC
energy consumption2018-19 324
3 VFD installation for pumps and fans 2018-19 15.4
4 Energy efficient coating on pumps 2018-19 0.29
5Interconnection hot water line with make up water line to switch off
filter feed pump in casthouse2018-19 0.482
6Current efficiency improvement in pots to reduce specific DC energy
consumption2018-19 101
7 Use of graphite particle instead of resistor coke 2018-19 1.65
Aluminium Business43
Adoption of New technology of Cell lining
Up-gradation of Pot Control & Feeding System
ROAD MAP TOWARDS BENCHMARK
MV drive for FTP ID Fan
HFO SCADA level-2 upgradation
“Measure to Control, Benchmark to Better”
Aluminium Business44
AWARDS & RECOGNITIONS
Recognition is the greatest motivator
✓ Recognized as “Energy Efficient Unit” at 18th
National Award for “Excellence in Energy Management” organized by CII.
✓ Silver award for best energy management from SEEM.
✓ PAT cycle-1 best achiever award from BEE.