Best Practices on Energy

Conservation
– Hindalco , Renukoot
Third Task Force Workshop
for Aluminium Sector
– Bureau of Energy Efficiency

Improved Energy Efficiency Through

Slotted Anode
19th August 2005
 Hindalco Renukoot
– A Journey
1962 2005
20,000 MTPA Production Capacity 342,000 MTPA
18.5 kWH/kg Energy Consumption 13.998 kWH/kg

Bauxite Mines

Co-Generation Alumina Caustic Soda

77 MW* Refinery From J.V.
Largest Integrated Renusagar
660,000 TPA*
Aluminium Smelter Aluminium
Aluminium Plant Power
Plant
342,000 TPA* Fluoride
From J.V.
741.7 MW*
- India Semi Fabrication
Plant

Redraw Rod Mills Rolling Mills Extrusion Presses

40,000 TPA 80,000 TPA 13,700 TPA

Silvassa
* Post Brownfield Foils Al. Wheel Plant
Expansion 5,000 TPA 300,000 WPA

Improved Energy Efficiency Through

Slotted Anode
19th August 2005
 Hindalco Renukoot
-An Overview
8358 workmen, 4109 staff

ISO 9000:2000 - July’1994

ISO 14001 – Apr’1998 2500 customers
OHSAS 18001 - Jan’2003 (150 international clients,
41 countries)
Integrated Operations

Continuous Improvement
Through WCM

Improved Energy Efficiency Through

Slotted Anode
19th August 2005
 Energy Conservation Path
• Technology Upgradation
• Energy Management System
• Energy Audits
• Continuous Benchmarking
• Review

Improved Energy Efficiency Through

Slotted Anode
19th August 2005
 Improved Energy Efficiency
through slotted anode
- A Case study

Improved Energy Efficiency Through

Slotted Anode
19th August 2005
 Plant Process - The Basics
Hall-Heroult Process
ALUMINA HOPPER POT COVERS
Pots – 2067 POINT FEEDERS

ANODE RING BUS ALUMINA

INSULATION
SiC BRICKS

Potrooms – 22 IS 6 BRICKS
FROZEN BATH
CRUST

TOE PLATE

Potlines - 11 CATHODE BUS BAR

ANODE
(+)
ANODE
(+)

MOLTEN CRYOLITE BATH ACD

MOLTEN ALUMINIUM

CATHODE BLOCK (-)

COLLECTOR BAR DENSE FIRE

BRICKS
CALCIUM SILICATE
INSULATION

Typical Hindalco Pot

Improved Energy Efficiency Through
Slotted Anode
19th August 2005
 Scope of Improvement
Power consumption (DC KWH/Kg Al)
= 298.06 x Pot Voltage
Current Efficiency (%)
Stores, Potlining,
Manpower
Selling dist, misc
7%
6% Alumina
33%

Power
Carbon
40%
13%

Bath Materials
1%

Improved Energy Efficiency Through

Slotted Anode
19th August 2005
 Pot Voltage drop breakup
S.N. DESCRIPTION VOLTAGE REMARKS

ANODE + CATHODE RING BUS OPTIMIZED BY INCREASING CROSS-

1 0.120
DROPS SECTION OF BUS BARS
2 DIAMOND DROP 0.003 MODIFIED SHAPE OF DIAMOND
3 CLAMP DROP 0.006 IMPROVED CLAMPING
IMPROVED CU-BAR THICKNESS FROM 1" TO
4 CU-ROD DROP 0.015
1.5"
CHANGEOVER FROM NUT BOLT
5 ROD-STUB DROP 0.017
ASSEMBLIES TO WELDED ASSEMBLIES
6 STUB-CARBON DROP 0.126 INCREASED STUB DIAMETER TO 130 MM
7 CARBON BLOCK DROP 0.135 CARBON QUALITY OPTIMIZATION
MODIFIED BATH CHEMISTRY OPTIMIZATION
8 BATH DROP 2.090
OF ACD
9 DECOMPOSITION VOLTAGE DROP 1.60 THERMODYNAMIC VOLTAGE
10 LINING DROP 0.328 OPTIMIZATION OF CATHODE CONSTRUCTION
11 BASE VOLTAGE OF A POT 4.440 TYPICAL FOR HINDALCO CELLS
EXTERNAL BUS BAR, CENTRE PASSAGE &
12 EXTERNAL & OTHER FIXED DROPS 0.055
OTHERS
13 TOTAL GROSS VOLTAGE/POT 4.495 RECTIFIER TO RECTIFIER

Improved Energy Efficiency Through

Slotted Anode
19th August 2005
 Gains Possible
• Save 0.10 V / Pot Æ Save 325 kWH / Ton (94% current
efficiency)
• 342000 MTPA x 325 kWH/Ton x Rs.1.484/kWH Î Rs. 1650
lacs per annum
• 342000 MTPA x 325 kWH/Ton Æ 111.15 mU Î Power saved
• (111.15mU/14.3 kWH/Kg)x10-3x106 Æ 7773MT Î Increased
Production
• Gain 7773 MT x 32000 /MT Î Rs. 2487 lacs / annum

Improved Energy Efficiency Through

Slotted Anode
19th August 2005
 Margin for Improvement
Bath drop
2 Volts

ACD = 4.5 – 5 CM
Pot Stability Loss Bath Resistivity
Pot Workability Loss Bubble
Resistance
Bath Composition
Current Efficiency Already optimised
Loss over years

Improved Energy Efficiency Through

Slotted Anode
19th August 2005
 The Idea
DR. S. WILKENING VISITS HINDALCO

• Idea Captured – Use • Could not provide

slotted anode to reduce information of exact
bubble resistance configuaration

• TASK FORCE FORMED: -

1. Mr. SC Tandon (Leader) 2. Mr. OP Srivastava
3. Mr. Arun Kumar 4. Mr. SC Mishra
5. Dr. RN Prasad 6. Mr. VK Bajoria
7. Mr. Rajesh Garg (Coordinator) 8. Mr. Ranmal Singh

Improved Energy Efficiency Through

Slotted Anode
19th August 2005
 Way forward - Brainstorming
• Slot configuration
• Slot creation methodology
• Scope, size and duration of experimentation
• Strategy to be followed and parameters to be
observed.

Improved Energy Efficiency Through

Slotted Anode
19th August 2005
 Brainstorming Solutions
• Lengthwise slot advantageous but difficult to produce
– produce widthwise slot.
– Look at possibilities for creating lengthwise slots.
• Initially create slots manually
• Limited slotted anode so experiment in 2 pots
• Pot voltage reduction
– in steps of 0.010 volts/pot
– Monitor pot performance during / after each anode cycle (25
days)
– Pot voltage, noise, butt area, butt thickness, search time,
current efficiency to be monitored for overall gains.
Improved Energy Efficiency Through
Slotted Anode
19th August 2005
 The modification
Slots, 2 Nos.
Height – 130 mm,
Width-13 mm

Original anode Slotted anode

Improved Energy Efficiency Through

Slotted Anode
19th August 2005
 The Journey of Slot creation
2 pots Æ potline #2 Constraint faced Æ cutting slot in workshop

Solution: Slot cutting in sample cutting m/c of carbon testing lab

Widthwise 2 slots 10 cm high Final height 13 cm [Bath ht. (18cm) – ACD(5cm)]

Pilot project after initial success Æ 18 cells (Potline #2)

Solution: - Use anode hydraulic press by putting 2 plates of the size
of slots.

Total Time: - 2 years Î Savings established : - 0.044volts/pot

Improved Energy Efficiency Through

Slotted Anode
19th August 2005
 Avg Volts/pot for
Results Average
Month Balance Cells of Volts/pot for 18 Saving
line-2 with Normal pots with
anodes Slotted anodes

Before using
Aug-00, As-Is
4.598 4.498 slotted anodes in
pots D19 to D36
Average
Sep-00 – Mar- 4.569 4.438 0.031
01

Average
4.539 4.404 0.035
2001-02

Average 2002-
4.569 * 4.425 * 0.044
03 (Apr-Aug)

•Power Severity Index increased from 5.0 during FY01-02 to 5.64 during FY02-03
Other operating parameters were also monitored for experimental pots, no significant
change/deterioration was observed.
Improved Energy Efficiency Through
Slotted Anode
19th August 2005
 Way forward – Mass
Implementation
Mass production in hydraulic press
not possible due to high rate of rejection Length wise slots
not possible in
Hydraulic press
Constraints Observed

Voltage reducing strategy

Difficulty in cleaning on mass scale?
of slots after baking

• Solution: - Vibro Compactor (w.e.f. Aug’03)

Improved Energy Efficiency Through

Slotted Anode
19th August 2005
 Slotted Anode Production
-Vibro compactor
100
90 93.1

80
% Slotted anodes prodn

70 72.5
60 61.0
53.8
50
46.6
40
30
25.1
20
10
0.0 0.0 7.1
0 0.0 2.0
0.0
Nov-03
Aug-03

Feb-04
Apr-03

May-03

Jun-03

Jul-03

Sep-03

Dec-03
Oct-03

Jan-04

Mar-04
Improved Energy Efficiency Through
Slotted Anode
19th August 2005
 Live Implementation
(Voltage reduction)

Experimentation: - 0.01volts/pot

Live: - As high as 0.05 volts/pot

Improved Energy Efficiency Through

Slotted Anode
19th August 2005
 The Impact
4.52
4.495 4.4914.495 Change over from
4.50 4.488
normal anode to
4.48 slotted anode &
4.489 Avg. 4.385 V
4.483 4.486 4.472 stabilization period
4.46 4.443 Slotted anode
V olts/P ot

4.44 4.449 4.43 After stabilization

Avg. 4.490 V 4.415
4.42 4.401
Normal anode 4.419 4.42 4.397
4.40 Before changeover
4.403 4.404 4.402 4.378
4.38
4.388 4.358 4.364 4.382
4.382 4.379
4.36 4.371
4.362
4.34
A pr-03
M ay -03

Jul-03

O c t-03
Nov-03
Dec -03

M ar-04
A pr-04
M ay -04

Jul-04

O c t-04
Nov-04
Dec -04

M ar-05
A pr-05
M ay -05

Jul-05
Jun-03

A ug-03
S ep-03

Jan-04
Feb-04

Jun-04

A ug-04
S ep-04

Jan-05
Feb-05

Jun-05
Improved Energy Efficiency Through
Slotted Anode
19th August 2005
 The Impact
14700 14606
14600 Change over from Avg. 13998
normal anode to Slotted anode
14500
14352 1437614360 slotted anode & After stabilization
14400
DC KW H/T Al

stabilization period
14300 14380 14376 14390 14210 14195
14261
14200
Avg. 14405 14073
14100 Normal anode 14151
14134 13999 14015
Before changeover 14083 14091 13979
14000 13939
13890
13900 13972 13974 13966
13949 13944 13917
13800 13896 13902
A pr-03
M ay -03

O c t-04
Jun-03
Jul-03
A ug-03
S ep-03
O c t-03
Nov-03
Dec -03
Jan-04
Feb-04
M ar-04
A pr-04
M ay -04
Jun-04
Jul-04
A ug-04
S ep-04

Nov-04
Dec -04
Jan-05
Feb-05
M ar-05
A pr-05
M ay -05
Jun-05
Jul-05
Improved Energy Efficiency Through
Slotted Anode
19th August 2005
 The Impact
64200
64000
63800 Avg. 62057
63600 Normal anode
63400 Before changeover
63200
63000
62800
Am ps

Avg. 63710
62600 Change over from
62400 Slotted anode
62200 normal anode to After stabilization
62000 slotted anode &
61800 stabilization period
61600
61400
61200
61000
A p r-0 3
M a y -0 3
Ju n -0 3
Ju l-0 3
A u g -0 3
S e p -0 3
O c t-0 3
N ov-0 3
D e c -0 3
Ja n -0 4
F e b -0 4
M a r-0 4
A p r-0 4
M a y -0 4
Ju n -0 4
Ju l-0 4
A u g -0 4
S e p -0 4
O c t-0 4
N ov-0 4
D e c -04
Ja n -0 5
F e b -0 5
M a r-05
A p r-0 5
M a y -0 5
Ju n -0 5
Ju l-0 5
Improved Energy Efficiency Through
Slotted Anode
19th August 2005
 The Result
Saving: - 0.105 Volts/Pot
(4.490 – 4.385)
Power Consumption below 14000 DC kWH/MT

Hindalco Smelter Æ better than 60% world production

in power consumption

Improved Energy Efficiency Through

Slotted Anode
19th August 2005
 Comparison
Power consumption figures (DC KWH/T Al) for global players:

• Guaranteed by Aluminium Pechiney, France (AP-30) - 13065

• Guaranteed by GAMI, China, GP-320 - 13460

• Benchmark, Alouette, Canada (AP-30 Technology) - 12600

• For Hindalco New Potlines 9,10 & 11, (Mar-04) - 13726

(Up-graded Vintage 1940’s Kaiser Technology, Small Size pots)

• Hindalco Average for all 11 Potlines (Mar-04) - 13896

(Up-graded Vintage 1940’s Kaiser Technology, Small size pots)

Improved Energy Efficiency Through

Slotted Anode
19th August 2005
 Financial Gains
Financial gains can be divided in two parts:
A. Reduction in energy Cost
Reduction in Voltage/Pot - 0.105 V/pot
Energy saving from Formula (@ 94.0% CE) - 341 KWH/T Al
Monetary benefits ( @342000 MT/annum prod ) - Rs. 1731 lacs/ annum
B. Increased Production Capacity:
It has already been established that increasing potline amperage can increase
Smelter production capacity.
Total power saved - 116.62 million Units/annum
Additional production using this - 8155 MT/annum
saved power (@14300/MT) Monetary benefits - Rs. 2610 lacs/annum
(@Rs. 32000/MT additional prod)
Total Annualized benefits can be as high as Rs. 4341 lacs/annum
Improved Energy Efficiency Through
Slotted Anode
19th August 2005
 Intangible Gains
• Environment: This initiative resulted in significant
reduction of Green House Gases emissions by almost
357.03 Kg CO2/MT or 122104 T CO2/annum (@
Smelter capacity of 342000 MT, CO2 Emission factor is
taken as 1047 gms/KWH based on IAI guidelines).

• In house designing of slots configuration, size & shape

built lot of confidence amongst employees.

Improved Energy Efficiency Through

Slotted Anode
19th August 2005
 Key Learnings
• The huge financial savings of Rs. 4341 lacs/annum
with hardly any investment

• First plant in world using slotted anodes on

commercial scale to reduce energy consumption.

• In house design of slots, size, shape etc, no external

reference used to design slots

Improved Energy Efficiency Through

Slotted Anode
19th August 2005
 Thank You!!!

Improved Energy Efficiency Through

Slotted Anode
19th August 2005