01 aluminium

7/31/2019 01 Aluminium

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First Prize Aluminium

HINDALCO INDUSTRIES LIMITEDHirakud Smelter, Hirakud (Orissa)

Unit Profile

HINDALCO industries limited (Hindustan Aluminium Company limited) is the largest manufactures ofprimary aluminium in India and also one of the largest manufactures in the world. HINDALCO is verticallyintegrated through every stage of the industry including bauxite mining, alumina refining, aluminasmelting, semi-fabricating (sheets and foils), product development and captive power generation.

HINDALCO Hirakud Smelter is located at Hirakud in Orissa. Hirakud smelter plant pursues production of

primary metal, which is based on electrolytic reduction. Expansion and modernization project forincreasing the smelting capacity to 146 KTPA presently is completed recently. In the last year Hirakudsmelter has successfully converted the HSS (Horizontal Stud Soderberg) Pots to pre-baked pots. Theconversion has resulted in high energy saving reducing the DC energy required for smelting process. Formeeting the extra power requirement the captive power plant at Hirakud is also expanded from 67.5 MWto 367.5 MW. HINDALCO Hirakud smelter has also taken a coal mine known as Talabira mines nearJharsuguda district of Orissa for meeting the coal demand of its power plant.

Hindalco Industries Limited, Hirakud


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Energy Consumption

With the implementation of various energy conservation projects and the conversion of HSS pot lines toPre-Baked pots has resulted in substantial energy reduction. There is steady decline of specific energyconsumption in the last three years. Below table and graphs shows

DESCRIPTION UNIT 2005-06 2006-07 2007-08

Annual production MT 66347 73008 99406

Total electrical energyconsumption/annum

Lakhs Kwh 11020 12480.77 16026.35

Specific energy consumption(electrical)

Kwh/tonne 15006 14935 14195

Total thermal energyconsumption

Mkcal 19108 19040.7 21668.28

Specific energy consumption(fuel)

Litres/Tonne 19.21 17.34 23.8

13600

13800

14000

14200

14400

14600

14800

15000

15200

2005-06 2006-07 2007-08

kwh/ton

year

total specific energy(electrical)

kwh/ton

0

5

10

15

20

25

2005-06 2006-07 2007-08

Ltr/ton

year

total specific energy(thermal)

Seri

Total Specific Energy (Electrical) Total Specific Energy (Thermal)


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SPECIFIC ENERGY REDUCTION

DESCRIPTION UNIT 2005-06 2006-07 2007-08DC energy for electrolysis Kwh /Ton 14942 14935 14000

Electrical energy forRolling ingot 1-20k CGand sow ingot.

Kwh/Ton 28.62 26.34 12.75

Energy Conservation Commitment Policy and Set up

HINDALCOs Hirakud Smelter management believes that energy and resource conservation are the twobuilding blocks for Hirakud Smelters sustainable development. The Plant has an Environment andResource Management (E&RM) cell which primarily focuses on energy conservation. The activities ofE&RM cell are reviewed once a month. Measurement, monitoring, managing and implementing new smallgroup activities / in-house projects/new technologies for energy conservation are the functions of this cell.The new proposals for energy conservation projects are discussed in the E&RM cell. Key issues likeconducting energy audit through external agencies and financial approval for identified energyconservation projects also constitutes the agenda of the meeting.

In an unending endeavor to improve the energy efficiency and capacity utilization, the company hasconstituted an apex body namely World Class Manufacturing (WCM) Steering Committee which isheaded by the Vice President. The World Class Manufacturing is a holistic approach, which incorporatesthe key features of contemporary initiatives and guides to excel in the field of energy conservation, waste

reduction and optimization of resource consumption. Under this concept, excellence and competitivenessgo hand in hand which facilitates and encourages all the employees to maintain abnormality freeenvironment and operating conditions. WCM Steering Committee constitutes of 12 WCM sub committeesunder which there are 48 operating teams across the entire cross section of the plant.

As a continued effort towards achieving excellence in the field of energy conservation, a Specific EnergyPolicy has been formulated for Hirakud Complex, which reflects the commitments of the top managementtowards conservation of energy, resources and environment. The unit is in fact the first Indian Company inthe aluminium sector to have formulated the energy policy. The said policy was also made public bypublishing it in one of the national newspaper The Times of India on 23 August 2002.

Having formulated the Energy Policy & involving people through SGA approach, the next priority for thePlant is the consolidation of the fundamentals of the Small Group Activities (SGA) at the grass root levelwhich is a challenge being faced by the Hirakud Smelters management. For reaping the advantages andthe benefits of a concept or a practice in order to add on to the bottom line of the company, the conceptsand the practices adopted need to be streamlined in the form of a well adopted system. Havingestablished and maintained three effective and internationally recognised systems viz QualityManagement System ISO 9001, Environment Management System ISO 14001 and Occupational Healthand Safety Assessment Series (OHSAS) 18001 at Hirakud Smelter, the company is in process ofamalgamating the best practices of all the three systems and thereby evolving a new common systemwhich will cater to the needs of all the three established systems besides the Energy Conservation andManagement at Hindalco Hirakud Smelter. The energy management structure at Hindalco Hirakud isgiven below


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Energy Policy

Energy efficient power generation, aluminium smelting and casting

Nurturing energy efficient designs and technology for all future acquisitions, where ever practicable

Enhancing utilization of renewable energy resources, wherever feasible

Recognizing efforts of our employees and their family members in energy conservation initiatives

Going beyond standards, wherever economically viable

Yardsticks, which drive us to monitor and improve energy performance through periodic reviewsand skill up-gradation of our employees.

Energy Conservation Achievements

Year No of SGA Investment(Rs lakhs)

Savings(Rs lakhs)

1999-2000 21 227 169

2000-2001 29 152 179

2001-2002 31 240 212

2002-2003 35 89 197

2003-2004 36 806 712

2004-2005 35 476 496

2005-2006 30 15048 888.56

2006-2007 20 45859.2 2047

2007-2008 15 21304.37 2076.248

Apex committee

Energy Monitoring Team

SGA Team

Coordinatingcommittee


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1. Reduction of DC energy in newly started 85KA prebake pots by implementation of anodeeffect termination (AET) technology

Before Installation:Before installation of this project the anode effectwas killed manually and it was very time taking andalso the anode effect duration was high.

Energy consumptionWhen HSS Power consumption was 14260Kwh/ton.During prebaked consumption is 14000Kwh/ton.Saving in FY-2007-08 is 425845560kwh.and

Rs.258lakh

After installation:In this project they have modified both hard wareand soft ware of the electronic pot controller. Afterthe modification the anode effect killing time hasreduced due to auto killing by the controller.

2. INSTALLATION OF VVFD FOR COLDWELL

MOTOR OF COMPRESSOR COOLING TOWER

Situation BeforeEarlier there was a star delta starter running themotor at full speed and as the pump is of highersize than requirement so the flow and pump of thewater line was adjusted with reducing valveopening. Due to reduced valve opening the pumpwas operating at lower efficiency and friction headlosses were more.

Situation After

After installation of VVFD the valve was made fullyopen and the pressure and flow is adjusted byvarying the motor speed through VVFD. Due to lowspeed operation the motor is operating with half ofthe power required before.Total investment-Rs.1.5lakhSaving-Rs.3.45lakh/year

Before

After


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3. REPLACEMENT OF OLD AIR COMPRESSORLINES

Situation BeforeThe compressor airline was forty years older andthere were many leakages in the line, due to thisleakage they had to run one more extra compressorfor meeting the load demand than the requirement.Also the airlines were laid under the tunnel, so itwas very difficult to maintain them.

Situation After

After changing of the old compressor line with new

one laid over head, running of one number ofcompressor was no more needed, so by this theyreduced one number of compressor to run.Total investment-Rs.15lakhSaving- Rs.6.4 lakh (recurring)

4. Demand based switching of air compressors

Before installation

There are 10 numbers of air compressors forsupplying compressed air to the pot line, most ofthem were running in unload condition for most ofthe time due to unavailability of sufficient controlmechanism, with this they were loosing a lot of noload power consumed by compressors

After installation

After using this PLC controlled circuit they hadsaved a lot of power by switching the compressorson the basis of load demand and with complete

closed loop control.Installation cost-Rs.60,000Saving-Rs.90,000/year


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Energy Conservation Plans and Targets

The following energy conservation related projects have already been identified for implementation in thePlant. Progress has already been made in few of these cases as on now.

S.NO ACTION PLAN TARGET

1 Conversion of existing 172pots to pre baked technology MAY-2008

2 Installation of auxiliary energy management system for monitoring ofauxiliary energy

AUG-2009

3 Installation of VVFD for IR compressor cooling tower Aug-2009

4 Installation of capacitor bank for plant auxiliary sub station Dec-2009

5 Replacement of old rectiformers of rectifier station Dec-2010

6 Installation of VVFD for compressor cooling tower Dec-2009

Environment and SafetyHINDALCO, Hirakud Smelter subscribes to eco-efficiency. In other words, it entails manufacturingproducts and providing services in a manner that conserves natural resources, minimizes wastes andensures pollution control. Because of the above approaches, the unit has been certified by BVQI for ISO9001:2000 in November 2001. Better environment management at HINDALCO, Hirakud Smelter hasenabled the plant to contain its production cost. At Hirakud Smelter an unending quest for environmentexcellence is demonstrated through implementation of Environment Management System 14001.


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Second Prize Aluminium

HINDALCO INDUSTRIES LIMITEDRenukoot, Sonbhadra (Uttar Pradesh)

Unit Profile

Hindalco Industries Ltd. (Hindalco), a Flagship Company of the Aditya Birla Group is a Pioneer non-ferrous metals powerhouse. Hindalco was incorporated in 1958. Its Renukoot unit was set up in technicalcollaboration with Kaiser Aluminium and Chemicals corporation, USA and commenced commercialproduction in 1962.

Hindalco, at Renukoot, houses a fully integrated plant, comprising of 3 main plants i.e. Alumina, Smelter &Fabrication Plants. Hindalco produces some Byproducts, which include Gallium Metal, Vanadium Sludgeand Aluminium Dross. Each plant employs varying Technology. With integrated facilities, output fromvarious plants is used by next, along with varying raw materials. Company has its own captive powerplant at Renusagar (30 Km away from Renukoot) with installed capacity of 741.7 MW and 78 MW of Co-Generation Plant at Renukoot itself.

Alumina Plant: - It was commissioned with an initial capacity of 40,000 MTPA, which has now increased,to 700000 MTPA. The plant has been expanded in phases using new technology from time to time forenergy efficiency and capacity enhancement. It employs the basic Bayers process and the major raw

materials for the plant are Bauxite, Steam, Caustic Soda and Furnace oil.

Aluminium Smelter: - It has 11 Pot lines with 2127 Pots installed with annual production capacity of3,45,000 MT. The Smelter employs the Hall Heroult Electrolysis Process for the extraction of Aluminiumfrom Alumina. Basic raw materials for the smelter are Alumina, Power, Anodes and Aluminium Fluoride.

Fabrication Plant (Value Added Products): - The Fabrication Plant at Renukoot comprises of 4 MainSections Remelt Shop, Cast House, Rolling Mills, Extrusion & Conform which produce Wire Rod,Slabs/Billets, Rolled, Coils and Extruded Products.

Hindalco, an ISO 14001, ISO 9001:2000 and OHSAS 18001 Company. Recently these three systemshave integrated as IMS (Integrated Management System).

Today Hindalco occupies a place of pride in the global aluminium scenario with its most efficient workingin all areas of operations. The company has kept pace all along with latest development in aluminiumtechnology and has upgraded its manufacturing facilities.

HINDALCO INDUSTRIES LIMITED


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Energy Consumption

Manufacturing of Aluminium is one of the most energy intensive process. The cost of Energy comprisesabout 41.40 % of the total input costs for producing Aluminium. Hindalco uses 3 types of Energyresources to manufacture Aluminium i.e. Coal, Oil and Electricity. Out of these three, electricity has thehighest share (almost 75.23 % of total energy consumption cost). Total cost of energy for last year wasRs. 893.23 Crore, which includes Rs.161.02 Crore for Fuel oil, Rs.672.01 for Electricity, and Rs.60.19Crore for Coal & purchased steam. Last year company consumed 491836 MT of Coal, 83263.20 KL ofFuel Oil, 61127.15 Lakhs kWh of Electricity and 264329 MT of purchased steam.

Specific Energy (Thermal M KCal/MT)

Specific Energy Consumption (Electrical Trends)

3.413

3.339 3.336

3.280

3.300

3.320

3.340

3.360

3.380

3.400

3.420

20 05 -0 6 2 006 -0 7 2 00 7- 08

YEAR

ALUMINA

0.503

0.487

0.462

0.440

0.450

0.460

0.470

0.480

0.490

0.500

0.510

20 05- 06 2006 -07 200 7- 08

YEAR

ALUMINIUM

0.320 0.330 0.329

0.000

0.050

0.100

0.150

0.200

0.250

0.300

0.350

2 00 5- 06 2 00 6- 07 2 00 7- 08

YEAR

Billet Casting

0.3200.290

0.255

0.000

0.050

0.100

0.150

0.200

0.250

0.300

0.350

20 05- 06 2 00 6- 07 2 007 -08

YEAR

CONDUCTOR REDRAW WIRE

444 444

432

425

430

435

440

445

kWh/MT

2005-06 2006-07 2007-08

Year

Alumina

1476214735

14710

14680

14740

14800

kWh/

MT

2005-

06

2006-

07

2007-

08

Year

Aluminium


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Energy Conservation Commitment, Policy and Set up

In the present scenario of increasing cost trend towards Energy, Hindalcos well-established EnergyManagement System is continuously working on Energy conservation. The company has a well-definedEnergy Policy to underscore its commitment towards Energy Conservation. To inculcate awareness onthe importance of Energy Conservation not only to the employees of the company but also to the society,the following setup is followed.

Setting up a dedicated Energy Cell with following agenda to enable the Company to reduce specific

energy consumption on continual basis and thus becoming one of the lowest cost producers in theWorld.

1. To identify potential area for energy saving in consultation with department.

2. To take care of latest technological developments in the field of energy conservation.

3. To suggest measures for better energy efficiency for the implementation in the plants and newprojects.

4. To monitor the quantum of energy saved on account of energy conservation initiatives.

Arrange Energy awareness program & National Painting Competition for School Children.

Arrange Energy Conservation program collaboration with IOC for Housewives on "Cooking Gas Proper Utilization of LPG", "Saving Energy at Home".

In-house and outside training program for staff & workmen for "Improved work practices for fuelefficient operation of Furnaces", "Fans" & "Cooling Tower".

Company encourages continuous improvement through small group activities under aegis of WCM inareas of Cost reduction, energy efficiency, quality and productivity improvement.

In line with Energy Conservation Act -2001 the company has trained 12 engineers to acquire thecertificate for Certified Energy Manager/Auditor awarded by BEE.

The Company believes in all the modern techniques like TPM, Quality Circle, 5S, TQM, WCM etc. and

is striving to become a World class Company in all its operations by creating awareness amongemployees towards energy conservation as well as resource conservation.

The company has well-structured suggestion scheme to encourage employees to give theirsuggestions for energy conservation and employees are suitably rewarded for viable suggestions.

328 329 328

300

305

310

315

320

325

330

kWh/MT

2005-06 2006-07 2007-08

Year

Billet Casting

59

62

57

54.000

57.000

60.000

63.000

kWh/MT

2005-06 2006-07 2007-08

Year

Conductor Re - Draw Rod


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Since the company has strong commitment towards Energy Conservation, the projects, which requireinvestments, are normally approved. Company takes special care to allocate funds for these projects.

A Top Down and Bottom Up approach through out the organization is maintained towards EnergyConservation.


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Energy Monitoring Methodology

A well defined Energy Management Organization Structure

Energy Conservation Achievements

The company has been receiving National Energy Conservation Awards, continuously since 1995. During2005-2008 company has implemented 177 measures to improve Energy Efficiency (including capacityenhancement) by investing Rs. 29.65 Crore which resulted in a saving of energy worth Rs.40.70 Crore /Year and also increased production.

Year No. of

measuresimplemented

Investment

made (Rs. InLac)

Savings

achieved (Rs.In Lac)

Energy Cost

(Rs. In Lac)

% Saving of

Energy Cost

2005-06 66 1,868.27 2,636.75 86,730.90 3.04

2006-07 67 914.88 754.40 87,325.94 0.86

2007-08 44 182.21 678.63 89,322.59 0.76

Total 177 2965.36 4069.78 263379.43 1.55


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Major projects implemented during the year 2007-2008

Adopting practice of low stub breaking andAnode setting activities together as well asclose monitoring of process parameters toincrease the pot's current efficiency. This hasreduced the specific Energy consumption byapprox 25 Unit/MT.

Investment - NilMoney saving = Rs.175.61 Lac/Year

Reduction in surface heat loss from Billet &

Cast House Furnaces by changing design ofrefractory insulation.

Investment 0.15 LacMoney saving = Rs.8.14 Lac/Year

Revamping of 3 Nos. Soaking Pit for improvedinsulation leading to reduced losses.


Reduction in Sp. Fuel Consumption of WireRod by improving combustion efficiency &

changing the SOP.


Special type (Insulyte-4)

Insulation castable

Furnace Roof


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To circulate the CEP water through the GlandSteam Condenser to increase the feed watertemp thus saving in coal consumption.


Interconnection of ACW and CW pump wasdone and two nos. ACW pumps were stoppedduring winter season to reduce the auxiliarypower consumption.


In addition of above, following 38 major projects have been implemented during FY 07 08.

SN PROJECT DESCRIPTIONSaving

(Rs.Lakhs)

Investment(Rs.Lakhs)

1Evaporation -3 Feed Pumps : Replacement of 150 HP motorsby 200 HP motors to avoid duplicate equipment running .

3.56 3.00

2Evaporation -3 Homo Liquor Pumps : Replacement of 150 HPmotors by 200 HP motors to avoid duplicate equipmentrunning .

3.98 3.00

3Installation of float switch to avoid idle running of New ETP Pitsump Pump

0.92 0.20

4Installation of energy efficient light in Evapn - 3, Coal tippler & PPTarea

0.15 0.15

5Control logic has been introduced on DCS to optimize the runningof additional condensate pump in precipitation area.

1.72 0.01

6Washer over flow pumps speed optimization as per washer overflow tanks level to reduce power consumption.

7.37 1.29

7Lime slurry feed pump speed optimization as per additive lime tanklevel to reduce power

2.05 0.65

8

Stopping the medium pressure purge water pump used for cooling

the gland of Digestion # 1 Blow off pump and bearings of Chargepump & Booster pump of Digestion # 1 & 2 by providing spool.

2.32 0.10

31.4MWTG

Condensate

B#3

Deaerator

e ector

5.6MWTG

land leak off

Gland steam

condenser

Raw

water

from

CT

Cooling

tower

basin

CW pp

Boiler &

turbine

auxiliary

Turbine

ACW pp


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9To stop one small cooling tower by providing the circulating waterto all the three bundles of flux cooler of FCB Calciner by increasingthe pipe dia from 4" to 6".

5.03 0.20

10Development of sweetening control scheme to run sweetening inboth Digestion unit # 1 & 2 through single pump instead ofdedicated pump.

5.80 0.50

11Development of Ball Bill idle run hour software for Ball Bill ofAlumina Plant in DCS for close monitoring. This has reduced thespecific energy consumption by 3 Units/MT.

38.28 0.00

12 Primary Feed System Blower stopped through air taken from air liftblower in FTP line-5, 6 & 7.

1.46 0.05

13 Primary air-slide fan of FTP line-8 stopped by capacity utilization ofair lift blower.

1.22 0.20

14 Filter hopper fluidization fan of FTP of Pot line # 5 & 6 stopped by

supplying the air from pot air slide fan.0.31 0.02

15 Energy saving by reducing pulley ratio of air lift blowers in Pot line-8 FTP.

0.54 0.06

16 Installation of transparent sheet in roof of Billet casting Area toreduce the ON time of roof lights.

0.38 0.56

17 Automation of cooling tower fan to control water temperature in therange of 28 to 33 Deg C.

1.31 0.05

18 Reduction in soaking time of few alloys at Billet Casting Homofurnace to reduce the power consumption.

1.80 0.00

19 Stopped the running of Sniff Nozzle during non casting time. 0.70 0.00

20 Making of Sow cake for sell from left out metal of furnace for

selected alloys (1050, 1060 &1070) after casting to reduce thescrap generation.

3.36 0

21 Provided the push button and indication lamp for air filter fan onthe operator panel of compressor to avoid the idle running.

0.09 0.02

22 Relocation of switch boards of Stack lights of Pot line # 6 to 11 toavoid the idle ON time.

0.11 0.02

23 Installation of automatic light sensor in Bath crushing area lights toavoid the manual intervention thus reducing the ON time.

0.03 0.01

24 Stoppage of Idle running of RAL motor of Pot line # 4 DSS secondphase.

1.18 0.25

25 Replacement of HTM heater with inline oil heater in Slab Casting

Furnace.

1.45 0.30

26 Revamping of Homo Furnace to decrease the heat loss. 0.48 40.00

27 Interlocking of circulating fan of Solution furnace to avoid the idlerunning.

0.10 0.00

28 Replacement of Motor of Caster scrubber unit pumps from 10 HPto 3 HP.

0.80 0.00

29 Interlocking of LNP coolant pump motor of Davy Cold Mill to avoidthe idle running of motor.

0.09 0.00

30 Feed water heater provided in Co-Generation - 1 to increase thefeed water temperature thus saving in coal. 53.80 15.60

31 Modification in pipe fittings of ash handling line of Boiler # 3 to

reduce false air ingress thus reduction in running hour of vacuumpump. 2.24 4.60

32 Modification in water pipe line of VAM to match the requirement. 7.05 0.50


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33 To stop the sample cooler pump by providing the connection fromraw water line.

1.30 0.50

34 Provision of on line removal of deposits from 5.6 MW turbine bythe use 100 PSI steam to increase the power generation. 100.80 2.00

35 Relocation of switches for lights of Boiler # 4 by-room to reduce theON time.

0.34 0.05

36 Installation of timer in lighting circuit of Co-Generation # 2condenser area lights to reduce ON time.

0.05 0.02

37 3 Nos. air compressors each of 11.2 KW discarded afterreplacement of Air Blast Circuit Breakers with SF6 Circuit Breakersat Rectifier-II.

1.67 0.00

38 Development of pump runs hour software for all power intensivepumps of Alumina Plant in DCS for close monitoring. This hasreduced the specific energy consumption by 7 Units/MT.

89.32 0.00

Besides above, a number of energy conservation projects have been completed through Small GroupActivities; only some of these have been included above.

Energy Conservation Plans and Targets

Energy Conservation MeasuresAnticipatedsaving (Rs.

Lakhs )

Approx.Investment(Rs. Lakhs)

Projectcommencementand completion

year

1

To convert existing high temperature Digestion

technology with energy efficient doubledigestion technology. 998.62 11885.00 2008-09

2

Construction of drain channels to connect allindividual sump pits in filtration area to avoid theindividual running of sump pumps to savepower.

2.18 0.75 2008-09

3

De-linking of Evapn. unit II and III for increasingevaporation rate on account of reduced BPRand stopping one pumping station and powersaving.

95.89 2.50 2008-09

4To arrest escapage of HRD waste vapors toheat wash water.

3.86 - 2008-09

5To enhance throughput of Ball Mill # 4 from 38to 48 TPH to reduce the specific powerconsumption.

12.00 41.20 2008-09

6

Efficient way of doing condensate cleaning ofprecipitation tank air lifts by process generatedhot condensate in place of clear water to savesteam energy for heating the same.

1.04 0.127 2008-09

7BM # 1 GMD Pump (N) -Motor Rationalization(25 HP-15 HP)

0.41 0.76 2008-09

8BM # 4 GMD Pump (N) -Motor Rationalization(60 HP-40 HP)

0.69 1.05 2008-09

9

Piping modification for rerouting Digestion # 3 &4 dilution lines through Washer # 1 over flowpumps thus removing existing pumping stationfor unit 3 & 4.

4.24 0.50 2008-09


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10Piping modification for catering requirement ofsweetening slurry for Digestion unit # 1 & 2 withone pump in place of two separate pumps.

3.79 0.10 2008-09

11Installation of capacitor bank in New Drum FilterMCC, Evp3 MCC, Old PPT MCC, BauxiteTippler MCC & Ammonia Compressor MCC.

0.77 - 2008-09

12Installation of energy efficient light fitting in PPT& Clarification area.

0.13 0.15 2008-09

13Spent Liquor Tank Agitator : Motor H.Prationalization (25 HP motor by 10 HP motor)

1.03 0.10 2008-09

14Installation of VFD in Main Air Slide motors ofPlant-2

12.2925.0 2008-09

15Reduce energy consumption by increasinganode life from 76 shift to 80 shift.

0.00 2008-09

16Reduce energy consumption by using biggersize cathode blocks in electrolytic pot. Trial tobe taken in 90 Pots in FY 08 - 09

7.260.4 Lakh /

Pot2008-09

17To reduce oil consumption by improving fluedesign.

2008-09

18Reduce steam consumption by using 100%molten pitch in paste plant 2008 - 09

19To stop the Rotary air lock of line-4 DSShoppers (Phase - 1) by providing a bypass linefor discharge of alumina in air slide

3.06 0.5 2008 - 09

20

Energy saving by optimizing the time of

fluidization of air slides of Automatic aluminaFeeding System of pot rooms by change in thePLC programme.

13.79 0.7 2008 - 09

21Optimize the running rpm of ventilation fans ofAlumina Transfer System between plant # 1 &plant # 2 through V.F.D.

1.13 0.5 2008 - 09

20Stopping of main air slide fan in FTP of Pot line- 9, 10 & 11 by utilization of additional capacityof filter hopper blower

4.90 1.2 2008 - 09

21Revamping of Homo furnace electrical controlsystem.

0.48 23.0 2008-09

22 Automation to avoid the idle running of coolingfan of Blue star STL DC motor. 0.29 Nil 2008-09

23Modification in hydraulic pipe line ExtrusionPress # 5 Platen saw so that one hydraulicpower pack could be eliminated.

5.44 Nil 2008-09

24Revamping of one no D C Melting & HoldingFurnace of Remelt shop to reduce RadiationLoss.

8.18 44.0 2008-09

25To install Variable Frequency Drive in the FDFan motor of Co-Generation unit # 1.

17.66 48.44 2008-09

26To install Variable Frequency Drive in the FDFan motor of Co- Generation unit # 2.

9.64 21.43 2008-09

27To replace Boiler # 2 de-aerator feed pump byEnergy efficient feed pump.

0.46 5.50 2008-09


18/18

28To install RO plant for polishing processcondensate coming from Alumina plant forsaving of water.

16.12 133.00 2008-09

29Bypassing of A/C cooling tower by providing thewater from transformer cooling tower in Pot line# 9, 10 & 11 Switch house Air conditioning units.

0.80 0.20 2008-09

Environment and Safety

Hindalco is totally committed to sustainable development; hence, building eco-efficiency in all of theiroperations. The company has a well-drawn out environmental management strategy in place.Environment concerns are textured into all manufacturing processes. In order to ensure that Hindalcocomply with all the stipulated environment norms, various state-of-the-art pollution control systems /

devices have been installed to prevent and control pollution.

With better awareness and appreciation towards ecology and environment, the organization is continuallylooking for innovative and cost effective solutions to conserve natural resources and reduce wastes.Capacity increase of the existing plant by process innovation, equipment modernizations etc withinsignificant increase of pollution load are some of the methodologies that highlight the strategies adoptedat Hindalco.

Updated fuel-efficient and particulate matter reduction technology (advanced ESPs) has been installed inCalciners and Boilers with Co-generation facilities. Microprocessor based controls and Advance DryScrubbing System installed in all Pot Lines to ensure less emission and energy.

01 aluminium

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