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Aluminium & Power, Jharsuguda

BEST PRACTICES ON ENERGY SAVINGS

SESA STERLITE LTD


JHARSUGUDA , ODISHA
Aluminium & Power, Jharsuguda
GROUP PHILOSOPHY
Our Mission Our Values

Excellence
Our mission is to be a Growth

world-class metals and Trust


mining group and generate Entrepreneurship

superior financial returns.


Sustainability

Our Vision
We will be the worlds Our DNA

most admired company that


Humble
consistently defines the
leading standards in our
businesses, making our
Hungry Smart
stakeholders proud to be
associated with us.
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Aluminium & Power, Jharsuguda
BUSINESS DIVERSIFIED
Sesa Sterlite, a Vedanta
Group company is one of the
world largest global diversified
natural resource company.

FTSE 100 London Stock


Exchange listed company.

Operations span across India,


Sri Lanka, Africa, South Africa,
Europe and Australia.

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Aluminium & Power, Jharsuguda
PLANT LOCATION

ODISHA

INDIA

PLANT
SITE

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Aluminium & Power, Jharsuguda
PLANT PROFILE
Capacity of 3615 MW

ISO 9001,14001,50001 & OHSAS


18001 Certified

Water Source Hirakud Reservoir

Coal Source- Mahanadi Coal Fields

High Concentration Slurry Disposal

Hybrid ESP with SPM level <


40mg/Nm3

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Aluminium & Power, Jharsuguda

IMPLEMENTATION & LEARNINGS

ISO 50001 ENERGY MANAGEMENT SYSTEMS

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Aluminium & Power, Jharsuguda

ENERGY MANAGEMENT TEAM- POWER

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Aluminium & Power, Jharsuguda

MILESTONES ISO 50001

CPP :

Kick-off ISO 50001:2011 30th Jan 2012

Stage-2 Audit (Certification Audit) 12th - 15th Sept 2012

IPP :

Kick off ISO 50001:2011 30th Jun 2012

Certification Audit 26th Feb 2013 to 1st Mar 2013

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Aluminium & Power, Jharsuguda

ENCON EFFORTS & BENEFITS


SHR = 2442 Kcal/kwh ; APC= 9.66%; SOC = 0.11 ml/kwh CPP
SHR = 2337 Kcal/kwh; APC= 8.08%; SOC= 0.38 ml/kwh IPP 2014-15

Implementation of Total Quality Mngt. Culture

Implementation of New Technologies


Implementation of IT Enablement in procuring Energy Efficient
Equipments
Improvement in Process & Operational Practices

Development and Implementation of Innovative and


Breakthrough Energy Efficiency Improvement Projects.
Daily Monitoring of Specific Consumptions & Deviation
Analysis
Energy Improvement Projects is linked to Individual KRAs
Energy Audit by CII in June11 & ISO 50001 implementation &
certification in the year of 2012
CPP 2010-11
SHR = 2678 Kcal ; APC= 10.14%; SOC= 0.80ml/kwh
SHR= 2430 Kcal/kwh; APC= 9.89%; SOC= 1.12 ml/kwh IPP 2012-13
4/29/2015 KEP WORKSHOP
Aluminium & Power, Jharsuguda

PROCESS IMPROVEMENT (9X135 MW)


1. Selective Soot-blowing:

Optimized need based soot-blowing resulting in flue gas exhaust temperature from
141C to 137C and reduction in super-heater spray by 2% that is 8 T/hrs.
Annual saving- 5.82 MTOE

2. Stoppage of purging of HFO guns:

Purging of HFO guns on regular basis are stopped


Annual saving- 35.93 MTOE

3. Optimization of key Process Parameters:

Operational optimization by maintaining the technical parameters like Main-steam


pressure, main-steam temperature , etc. near to design value.
Annual saving- 3.17 MTOE

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Aluminium & Power, Jharsuguda

PROCESS IMPROVEMENT (9X135 MW)


4. Cooling Tower fan door plugging:

Plugging of the holes of Cooling Tower fans, hence reduction in fan loading via
excess air leakage and improvement in vacuum.
Annual saving- 22.14 MTOE

5. Optimized use of Compressor:

Stoppage of Dryers in Service Air system (6 nos.)


Arresting of leakages and rectification of intake valve passing resulting in stoppage
of 1 compressor.
Annual saving- 188.31 MTOE

6. Optimized running of Dry Ash conveying system:

Running of Dry-Ash conveying system in level mode from timer mode resulting in
stoppage of 1 compressor.
Annual saving- 188.31 MTOE

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Aluminium & Power, Jharsuguda

PROCESS IMPROVEMENT (9X135 MW)


7. Optimization in Electrostatic Precipitator :

The 1st Field ESP hopper heaters are switched off during normal running of the
units.
Each hopper consist of 2 heaters of 3Kw each.
Annual saving- 72.31 MTOE

8. Improvement in Belt utilization:

Improvement in Belt utilization by rectifying the track hopper, ILMS (In-line


magnetic separator and replacement of existing conveyor with the new conveyor.
Annual saving- 65.34 MTOE

9. Operational Optimization of Mills Lube-Oil pump:

Stoppage of stand-by Mills Lube-Oil pump


Annual saving- 45.19 MTOE

4/29/2015 KEP WORKSHOP


Aluminium & Power, Jharsuguda

PROCESS IMPROVEMENT (4X600 MW)


1. Increase Reheater temp(528C to 538C):
Daily Monitoring HRD sheet
SADC checking(S/D)
Burner tilt operation
Increase in HRH temp from 528 to 538C
Unit heat rate improved by 2 kcal/kwh
Annual saving- 1653 MTOE

2. Identification and plugging of air ingress points in flue gas ducts


Flue gas, air duct leakage detection resulting in ID FAN Avg. current reduced from 246 A to
234 A. (power reduce by 0.5 MW) &.083 % APC reduction
Annual saving- 376 MTOE
3. PA Fan power reduction by arresting air leakage
Seal air leakage detection and PA hot air and cold air to mill leakage detection in U#2
resulting in PA FAN A- Current reduced from 106 A to 86 A and PA FAN B-108 A to 82 A
(Power reduced by 0.95 MW) APC reduced by 0.158 %.
Annual saving- 715 MTOE

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Aluminium & Power, Jharsuguda

PROCESS IMPROVEMENT (4X600 MW)


4. Optimization of idle running hours of drives:
Stopping of One CW pump as per circulating water inlet and outlet
temperature.
Annual Saving: 393 MTOE/Unit
Stopping of one Vacuum pump as per condenser Vacuum
Annual Saving : 216 MTOE/Unit
Stopping of DP pump for makeup in condenser.
Annual Saving - 203 MTOE/Unit
Implementation of shutdown checklist to Stop the running equipment
Annual Saving - 144 MTOE/Unit
During Unit Startup use TDBFP instead of MDBFP
Annual Saving - 120 MTOE/Unit
Stopping of 1 seal air fan(250 kw) by arresting seal air leakages
Annual Saving: 41 MTOE/Unit

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Aluminium & Power, Jharsuguda

PROCESS IMPROVEMENT (4X600 MW)


5. Reduction of start up time: Very hot Start up
Six Sigma project implemented to reduce very hot startup 1.50 1.60
1.16
Step by step activity/process prepared 1.00

Very hot startup time reduced to 1hr 35min to 1hr 10min 0.50

saving- 63 MTOE 0.00


before after

6. Reduction of startup time by Deaerator pegging in boiler and turbine preheating


Boiler feed water temp increased to 121C (earlier 50C) by deaerator pegging. Which
raised the furnace temp to 97C (earlier temp was 40C).Time reduced to 20 min
During turbine preheating ,HP inner /outer casing temp was raised to 204 /192 C instead
of 150C ,which has reduced the time of heat soak by 2 hrs.
SAVING : reduction in oil consumption during startup to 121 MTOE
Reduction in time by heat soaking Reduction in time by increasing furnace temp
5 4.5 3
2.29
4 2 1.52
3 2.5
1
2
1 0
before after before after
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Aluminium & Power, Jharsuguda

PROCESS IMPROVEMENT (4X600 MW)


7. Reduction of Number of Trips :
Identify the root cause of all unit outages
Implement recommendation of Trip analysis
saving- 150 MTOE/Unit

8.Reducing the output voltage of lighting transformer


No of taps were reduced in lighting transformer with a reduction in voltage from 432 volts to
415 volts resulted in power saving of 30.2 Kwhr per day
Annual Saving: 1 MTOE

9.Increasing ash utilization by disposing Ash through trucks


Reduction of ash conveying from transfer silo to terminal silo, as D-pump ash conveying
capacity averagely 260tns/hr. Stopped one compressor.
Geho pump dispose 260T of ash per hour. As 4,500T of ash transported through trucks,
per month 18 hours of Geho running hour reduced.
Saving of 10654 kwhr power per month and specific power: 0.05 Kwhr/MT
Annual saving: 7 MTOE

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Aluminium & Power, Jharsuguda

PROCESS IMPROVEMENT (4X600 MW)

10.Increasing CHP conveyor belt utilization

Increasing coal conveyor belt utilization from 50 % to 60 % (from 1500 TPH to 1980 TPH)
to minimize the power consumption with saving of 922 MWhr
Annual Saving:97 MTOE

11. Reduction of Rake Turn Around Time


Elimination of idle running time of stream and compressor with a saving of 263 MWhr
Annual Saving: 22 MTOE

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Aluminium & Power, Jharsuguda

TECHNOLOGY IMPROVEMENT (9X135 MW)


1. Condenser Cleaning (Jet, bullet & chemical):

Condenser Jet cleaning=1 unit; Bullet cleaning=4 Units; Chemical cleaning=1 unit
Average improvement of 20 kCal/kWh/Unit/Kpa in Heat Rate.
Annual saving- 148.74 MTOE

BEFORE AFTER

4/29/2015 KEP WORKSHOP


Aluminium & Power, Jharsuguda

TECHNOLOGY IMPROVEMENT (9X135 MW)


2. Air Preheater seal and basket replacement :
Air Preheater Baskets and soft touch seals replaced resulting in Improvement of
boiler efficiency by 0.5%
Reduction in Primary Air Fan (PA) loading of 103 Kwh
Annual Saving: 620.50 MTOE

BEFORE AFTER
4/29/2015 KEP WORKSHOP
Aluminium & Power, Jharsuguda

TECHNOLOGY IMPROVEMENT (9X135 MW)


3. CT Fans Blades Replacement :
For each unit, 5 CT cells are designed.
Weight of GRP blades is more than FRP blades.
Total 13 nos. of GRP blades replaced with FRP blades.
Average Savings : 234.70 MTOE.

BEFORE AFTER
4/29/2015 KEP WORKSHOP
Aluminium & Power, Jharsuguda

TECHNOLOGY IMPROVEMENT (9X135 MW)


4. Replacement of Old Chrome rollers with New
Sinter Cast Rollers & Liners
Rollers & Liners are replaced by New Sinter
Cast Rollers
Reduction in Mill power consumption by 30 KW.
Running hours increased from 6000 to 18000
hrs.
Savings : 17.54 MTOE.

BEFORE

4/29/2015 KEP WORKSHOP


Aluminium & Power, Jharsuguda

TECHNOLOGY IMPROVEMENT (9X135 MW)


5. CW pump Impeller coating:

CW pump impellers coated with


Brush able coating

Reduction in CW pump loading


by 68 kw

Annual Saving: 45.19 MTOE.

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Aluminium & Power, Jharsuguda

TECHNOLOGY IMPROVEMENT (9X135 MW)


6. Ultrafilteration Installation to Reduce DM Water Consumption:
Installation of Ultrafiltration System to reduce the colloidal silica in
Demineralized (DM) water.
Reduction of Blow down losses by 80% & heat losses.
Annual Saving: Rs. 213.62 Million.

Ultra-filtration System
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Aluminium & Power, Jharsuguda

TECHNOLOGY IMPROVEMENT (9X135 MW)


7. Modification of Fly Ash Conveying System:
Due to modification the consumption of compressed service air reduced
resulting in stoppage of 2 compressors.
Each of the units was provided with a separate air vessel to compensate the
fluctuations.
The ash collection vessel size was increased for ESP 3rd field and same was
placed in 4th field
Annual Savings: 376.61 MTOE

BEFORE AFTER
4/29/2015 KEP WORKSHOP
Aluminium & Power, Jharsuguda

TECHNOLOGY IMPROVEMENT (9X135 MW)


8. Installation of Eco Ventilators :

Earlier Turbine hall & compressors house consisted of 72 & 16 electrics fans
respectively.

Each fan rated capacity 3 kw.

Electric fans are replaced by Eco ventilators (224+28) in TG Hall as well as in


Compressor house.

Energy savings : 199.39 MTOE

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Aluminium & Power, Jharsuguda

TECHNOLOGY IMPROVEMENT (9X135 MW)


Project :
Utilization of Waste Water :Effluent Treatment Plant - 2 (ETP) Commissioning.
Before: After:

Waste water management by


More than 4000m3/day of waste treatment in ETP
water was discharged out of the Zero discharge of water out of
plant plant
Specific water consumption was Specific water consumption is
high reduced

CPP Synergy Office CPP Switchyard CW Pump Area CT Fans Area

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Aluminium & Power, Jharsuguda

TECHNOLOGY IMPROVEMENT (9X135 MW)


Project :

ESP Bag Filter Retrofitting.


Before: After:

Designed ESP had 5 fields Last 2 fields replaced with Bag filter
Ammonia dozing was in process Ammonia dozing stopped
Avg. SPM was more than 100 Existing Ash Conveying system is
mg/Nm3 modified
Avg. SPM < 30mg/Nm3

BEFORE
BEFORE

AFTER

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Aluminium & Power, Jharsuguda

TECHNOLOGY IMPROVEMENT (4X600 MW)


1. Boiler Modification(LTSH,ECO,RH):
Reduced the surface are of LTSH tubes and increase the contact area of economizer
bank which resulted in SH spray reduction and increase in feed water temp.
The modification includes
LTRH zone curtailment by 120 tubes
Installation of riffled tubes over exposed furnace water wall tubes
LTSH tube curtailment by 1 bank
Economizer zone extension by 1bank.
Annual saving- 4745 MTOE

2. Power reduction in CW pump due to speed reduction


Addition of no of rotor poles from 16 to 18 in CW pump in U#4 for speed reduction saving-
0.233 % APC CWP current reduced from 290 AMPS to 235 AMPS and 1.4 MW saving in
power consumption
Annual Saving: 520 MTOE
BEFORE
3. Reduction of power in CEP after removal of one stage
Removal of CEP stage in order to compensate energy loss due to throttling of deaerator
AFTER
level control valve resulting in CEP Pump-Current reduced from 123A to 92 A. (0.45 MW
power reduced & 0.075 % APC
Annual saving- 167 MTOE
4/29/2015 KEP WORKSHOP
Aluminium & Power, Jharsuguda

TECHNOLOGY IMPROVEMENT (4X600 MW)


6. VFD installation in BA slurry pump

Installation of variable frequency drive in bottom ash slurry pump in U#1,U#2 with a saving
of 68 Kwhr
Annual Saving: 45 MTOE

Before After
RPM 990 700-750
KW 135.5 67.3
KVA 160.1 68.4
KWH 3313 1152
KVAH 3881 1168

7. Indigenization of ID fan motor


U#1 ID FAN 1A motor replaced with CGL make with a net saving per day with a new motor
BEFORE
@ 60kw. In addition to this there is a saving due to stoppage of 1 cooling fan having power
consumption 7.5 kw and one lube oil pump having power consumption 1.1 kw
Annual Saving: 9 MTOE AFTER

4/29/2015 KEP WORKSHOP


Aluminium & Power, Jharsuguda

TECHNOLOGY IMPROVEMENT (4X600 MW)

8. Implementation of auto timer in lighting system

Earlier for lighting there is no time limit .We have installed timer for illumination in different
area with a saving of 62 kwhr
Annual Saving: 1.95 MTOE

9.Use of induction lamp in mill coal feeder


Incandescent lamp of 40 w were replaced by induction lamp of 18 Watt in all mill coal
feeders of U#1,U#2 and U#3 with a saving of 528 Kwhr per feeder per day
Annual Saving: 1 MTOE

10.Installation of EPIC-3 controller in ESP field


BEFORE
In U#2 ESP field controller from Dalian Chinese make to EPIC-3 controller with a flexibility
of changing field charge ratio resulted in saving of 240 kwhr per day
Annual Saving: 1 MTOE AFTER

4/29/2015 KEP WORKSHOP


Aluminium & Power, Jharsuguda

TECHNOLOGY IMPROVEMENT (4X600 MW)


11. Mill Hot air gate modification and mill lube oil system modification :
Mill Hot air gate modification and mill lube oil system modification in all 4 units resulting in
reduction of oil consumption by increasing equipment availability which is equivalent to
decrease in SOC by 0.2 ml/Kwhr
Annual saving- 159 MTOE

BEFORE

AFTER

Mill HAG Modification Mill Lub oil system modification

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Aluminium & Power, Jharsuguda

DAILY MONITORING

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Aluminium & Power, Jharsuguda

DAILY MONITORING
Monitoring system
Integrated Energy Meters are installed for HT &
LT motors and configured in DCS. Meters used
for all measurements are calibrated as per ISO
Standards
Related Process parameter are displayed on
the DCS screen.
All relevant energy data is captured from these
resources at regular intervals by PDHR data.

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Aluminium & Power, Jharsuguda

TQM CULTURE

5S Certified
5S structure, zones created & effective audit is in place.
5S Awareness sessions are conducted for direct & indirect
employees
6 zones and 24 Subzones
Total employee engagement in 5S is 128 direct & 450
indirect

Quality Circle/ Lean Quality Circles


Awareness training completed for 360 employees
(SSL & Service provider)
Total 20 QC teams formed Including SSL employee
and Service providers
Total 140 SSL employees and service providers are
engaged in this initiative

Sig Sigma
Wave-3 has 9 top priority projects driven by 55 employees
4 Team Leaders qualify for Black Belt Certification and 24
Team Members would qualify for Yellow Belt Certification.

4/29/2015 KEP WORKSHOP


Aluminium & Power, Jharsuguda

ENCON SUMMARY IN 3 YEARS

CPP :
2482.82 IPP : 10595
MTOE MTOE

Total
Savings:
13077
MTOE

Total Savings: 13077 MTOE

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Aluminium & Power, Jharsuguda

AWARDS & RECOGNITION

Engineering Excellence Excellent Energy


Awards 2014 Efficient Unit 2014

7th India Power


Top Plant Award -2014 Award 2014

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Aluminium & Power, Jharsuguda

AWARDS & RECOGNITION

Engineering Excellence Excellent Energy


Awards 2013 Efficient Unit 2013

6th India
Power Award
2013

National Energy Conservation National Energy Conservation


Award-2012 Award-2011

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Aluminium & Power, Jharsuguda

THANK YOU

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