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Vedanta Limited, Aluminium - BALCO | 1

Balco Overview

Bharat Aluminium Company (BALCO) has made significant contributions as

the,1st PSU in India’s Aluminium sector Incorporated in 1965, BALCO is

India’s first integrated Aluminium business.

One of the first disinvestments of the Government of India. It now a part of

Vedanta Limited, with 51% stake held by Vedanta Limited and 49% held by

Government.

Balco is based in Chhattisgarh State having Captive Bauxite mines in

Mainpat and Kawardha, Captive coal mines in Chotia, 2010 MW power

generation capacity and 5.7 LTPA Aluminium Smelting capacity at Korba

Complex.

Balco produces Wire rods, ingots, Alloy rods, Alloy ingots and Rolled

products. Balco is also selling power.

Balco has been India’s first - to have Captive Power Plant, to venture into +

300kA Prebake pots, to produce Alloy Rods for conductors used in power

transmission industry, to roll material for Aerospace in the Country, online

riser replacement and busbar insulation in potroom and single beam

implementation, holds patent for aluminium cell fuse technology.


Process Flow –Aluminium Production

Prebaked Rodded Anode

Butts

Crust

Bath

Fumes after

Dry scrubbing

FumeEnriched

Al2O3

Cast house

DC Power

Cryolite, Soda, ALF3

Bamboo

UtilitiesAir

Carbon

Liquid Al

To the air

Central Store

FTP

Electrolyte cell

(Pot)

Captive Power Plant

Stack

- Electrical Power as

part of COP – 38%

- Electrical Power as

part of energy

consumption – 98%Prebaked smelting processes (Hall Heroult) involve electrolytic reduction

of the Alumina by Carbon to Hot metal and Carbon dioxide.

2 Al2O3 (dissolved) + 3C(s) ------> 4Al(l) +3CO2(g)

Technology Provider –

Potline1 GAMI (320KA),

Potline2 GAMI (340KA)


Certifications, Energy Policy and Objectives

1. Reduce Net AC Power consumption to 12720 KWH/Mt-Al

2. Reduce Auxiliary Power Consumption to 380 KWH/MT-Al

ENERGY OBJECTIVES (Vision FY21) :ENERGY OBJECTIVES (FY18) :

1. Reduce Net AC Power consumption from 14139to 13680 KWH/Mt-Al

2. Reduce Auxiliary Power Consumption from 438to 417 KWH/MT-Al

S. No Description Certification

1 Quality management system ISO 9001:2008

2 Environment Management System ISO 14001:2004

3 Occupational Health & Safety

Management System

OHSAS 18001:2007

4 Energy Management System ISO 50001:2011

5 Asset Management System ISO 55001:2014

6 International Automotive Task force TS 16949


Energy Conservation Journey & Review Mechanism

Corporate Sustainability Review

Monthly Management Review by CEO

Monthly Operational Review by Plant Head

Weekly Energy Cell review by Energy

Manager

SBU Level review – Daily War Room

Energy Excellence Model

Bench-

marking

Innovatio

nAwareness

Involveme

nt

Certific

ation &

Awards

Energy Saving, Cost

Reduction, Sustainable

Operation


Global benchmarking & Energy Conservation Vision 2021

54.451.1 50.8 49.3 49.2 48.6 49.1 48.5 47.5 45.8

FY 14 FY 15 FY 16 FY 17 Indian BenchmarkInternational Benchmark FY 18 FY 19 FY 20 FY 21

Energy Consumption (GJ/MT)

S. No. Major Projects / Action Plan for Vision FY 21 Power Saving UnitTarget

Completion

1 Reduction in Pot-line Aux. power consumption to 380 KWh/MT 53 Kwh/MT Dec-17

2 Installation of 100% graphitized Cathodes 48 Kwh/MT on monthly basis Mar-20

3 Up gradation of Pot-control system in Pot-line 1 250 Kwh/MT Feb-18

4 Up gradation of Pot-control system in Pot-line 2 250 Kwh/MT May-18

5 Increase in Pot-line Current Efficiency from 93.38 to 94.48% 140 Kwh/MT Mar-18

6 Installation of air cooled cathode tabs in collector bar 400 Kwh/MT Sept-19

7 Installation of Energy efficient RUC cathodes 700 Kwh/MT Mar-21


13

47

1

13

49

8

13

55

9

13

62

1

13

64

3

13

74

0

13

90

1

14

02

9

14

43

9

12

78

0

12

90

4

13

21

1

13

34

0

13

36

5

13

38

0

12

70

0

12

45

0

12

10

0

Potline DC Sp/ Power Benchmarking


Major Energy Conservation Projects

S.No Title of Project

Annual Energy

Saving Million

KWH

Investment

Million

INR

1 Energy reduction in Utility area (Compressor and pump houses) 3.6 -

2 Use of 100% Graphitized Cathode (done in 98 pots) 44.71 84.6

3

Cast House 2- 1. LTA to be reduce to 15 min so has to utilize metal heat from

Pot-room,2.Improving Air to oil Fuel ratio in HF 1 and HF 2 for less oil

consumption. 0.3 -

4Rodding 2- 1. Minimize idle running hours in all bet conveyors,2.-Installation

of timers in all De-dusting unit,3.Induction Furnace Process Optimization. 0.09 -

5Installation of 10000 18 W LED tube lights in place of 40 W conventionaltube lights through EESL scheme 0.91 1.9

6Installation of Motion Sensors for lighting control in Washrooms / Conference

room

0.09 0.3

7 Installation of no's 420 90W LED Street lights in place of 250W HPSV 0.3 3

8 Installation of LED Down-lighter lights in Canteens 0.04 0.34


S.No Title of Project

Annual Energy

Saving Million

KWH

Investment

Million

INR

9 Close loop provision in Compressor & Rectifier pump house -1 & 2 0.3 4.5

10 One compressor Air end up-gradation 1.72 2

11 Conversion of Lighting load to Solar 1.63 9.6

12 Installation of VFD for Cold well pumps in ACH 0.3 2.5

13 NCRM AC Plant cooling water system to be merged with RCW line. 0.3 0.5

14 Use of Induction Cooktop in place of Nichrome based heaters in Canteens. 0.15 0.5

TOTAL 55.47 110.64

Major Energy Conservation Projects Contd.

FY Project DescriptionInvestment

(Rs. Crs)Turnover (Rs. Crs)

% Investment on Turnover

2016-17 100% Graphitized Cathodes 84.6 6400 1.3%

2017-18 Pot Controller upgradation and 100% Graphitized Cathodes 154.1 9063 1.7%

2018-19 Cathode Air cooled taps and 100% Graphitized Cathodes 126.2 9063 1.4%

%Investment for Major Energy conservation projects on Turnover


Project Start Date : 01-04-2016

Project End Date : 31-03-2017

Problem Statement:- The specific power consumption

was more than 13,300 KWH/MT of hot metal for semi

graphitized cathodes.

Data Collection :- To collect the historical data, pots

were chosen having same cell design, located within

same pot line and similar age. Cathode voltage drop

(CVD) and wear rate of cathode were taken as

performance indicator.

Project 1-100 % Graphitized Cathode with variable slot depth design

Specific Power Consumption of Semi graphitized

cathodes:-

S No. Cathode Block Power Cons.

(DC)UOM

1 Semi graphitic A 13286

KWH/MT of

Hot Metal2 Semi graphitic B 13349

3 Semi graphitic C 13412


C

3D graphical representat ion of the VSD

Collector bar

Slot VSD

Cathode-bottom block

1. ACD (anode to cathode distance) reduction was also given priority as energy reduction was the objective but it

comes with the adverse effects of decreasing the pot temperature and instability. Variable slot depth design

(VSD)was developed to manage this problem, SD gives more homogeneous current density distribution and there

by increased stability which allows ACD reduction.

2. The higher thermal conductivity of graphitized cathode compared to semi graphitized cathodes, required added

insulation within the cell lining to maintain the same thermal balance without increasing the energy required to

operate the pot.

New lining design keeps the heat in the pot, i.e. reduces thermal losses.

Uniqueness of the project


200

220

240

260

280

300

320

340

360

380

400

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55

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5

25

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35

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45

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55

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70

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75

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80

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85

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90

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95

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10

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10

55

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55

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05

12

55

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05

13

55

14

05

14

55

15

05

CV

D (

in m

v.)

Age (in Days)

CVD Trend of different cathodes

Data Analysis, Countermeasures & validation

Wear rate comparison:-

S No. Cathode Block Max wear

rate(mm)

Predicted life

(Days)

1Graphitized

cathode with VSD68,8 2613

2 Semi graphitic A 139,8 1356

3 Semi graphitic B 145,8 1073


Results:- Cathode Voltage Drop and wear rate has been substantially lowered than reference semi graphitized

cells and leading to reduction in Specific Energy Consumption and satisfying project target.

Comparison of measured CVD

between Reference semi graphitic

cathodes and graphitized cathodes with

VSD

Results Achieved/Results Achieved

Specific Power Consumption of cathodes:-

S.No Cathode Block

Power

Cons.(DC) UOM

1

Graphitized Cathode

with VSD 12700 Kwh/MT of

Hot Metal2 Semi graphitic A 13339

3 Semi graphitic B 13348

Benefits to organization:-

Tangible Benefits:

1. Energy saving-13500000 Kwh/Year (560

Kwh/TON)

2. Energy Cost saving-405 Lakh Rs/Year


Project 2 - Energy reduction in Compressor and pump houses



Problem Statement:- High energy consumption in utility area (Compressor and pump houses).

Data Collection

Specification of pumps.

Power consumption reports sampling.

Rectifomers temperature status.

Operation parameter of RPH.

Cooling temperature of all cooling towers.

Departmental Air flow measurement data.

Compressor air flow and pressure data.

Operation parameter of both compressor

houses

Data Analysis & Validation

Before project power consumption .

Feasibility analysis of automation of CT fan.

Temp. range margin available or not in system.

Parameters monitoring of cooling tower:(approach and

range).

Blade angle measurement and position and setting.

Analysis of pressure and flow variation of both compressor

house

Measurement of Motor & Pump efficiency.


BEFORE PIPE LINE NETWORK

Hot Water line

Pump house

Cold Water line

RE

CT

IFIE

RS Cold Water Return line

PUMP HOUSE

CT#1 CT#2 CT#3

COLD WELL HOT WELL

V

V

AFTER PIPE LINE NETWORK

Hot Water line

Pump house

Cold Water lineR

EC

TIF

IER

S Cold Water Return line

MODIFICATION DRG FOR CLOSE LOOP OF COLD WATER PIPE LINE IN RPH 1

Grean pipe belongs to new modification with two valves

PUMP HOUSE

CT#1 CT#2 CT#3

COLD WELL HOT WELL

V

V

New system by pass the hot well

New close loop pipe line

HOT WELL

COLD WELL

Measures for energy reduction

To modify the cold water circulating line by Close loop system in Rectifier pump house.


Power saving approx. 2.3 MWH/day by

stopping of two 45 KW pump

Water saving 36m3/day by reduction of evaporation

loss

Results achieved


Cooling tower blade angle

adjustment for effic. increment

Impeller trimming before and after Cooling tower automation

Measures for energy reduction


By close loop project : 2.3 MWH/Day (840 MWH/Year)

Total saving: 2995365 INR/ Year

CT automation= 345.6 KWH/Day (126144 KWH/Year)

Total saving : 378432 INR/Year

CT Effic. Increment = 22 KWH /Day (8030 KWH/Year)


Compressor interconnection

Saving /Day : 9 MWH/Day (3285 MWH/Year)


Trimming of impeller

500 KWH/Day (182500 KWH/year)

Total saving : 5,47,500INR/Year

Grand total saving:13800387.00 INR

Valve operation has been reduced up to zero

level.

Improvement in Team work &

Communication.

After Integration we can run Pot line 1 with

Potline-2 Compressor House and vice versa in

case of complete tripping.

No need of reducing Pot line Amperage

during Compressor house major Shutdown.

Tangible Benefits Intangible Benefits

Uniqueness of closed loop projectSaving achieved = Mandays Reduction +50%

Chemical Reduction+ Water Consumption

Reduction+ Power Reduction

Horizontal deployment is going on various

areas :–Compressor pump house -1,Rectifier pump

house-2 ,Rodding pump house.

Benefits to organization:-Benefits to Organization


Project 3 - Melting/Pre Heating of ladles using used oil & Reduction of Diesel consumption

.

Data Collected

Total Consumption & cost of diesel & used oil.

Practice and process

Temperature in ladles

Data Analysis ,Countermeasures

Use of electric preheater for preheating but -it required heavy expenditure.

Used of LPG gas for preheating but -it required heavy expenditure.

Pre heating time to be reduced but- impact quality (Non compliance)

Reduce the timing of melting but -the solid metal unable to melt.

Using of Used oil.

Validation & Results

Mixing 80:20 diesel and used oil ratio we got success.

Mixing 40:60 diesel and used oil ratio we faced problem in firing.

Mixing 45:55 diesel and used oil ratio we found awesome Result.



Problem Statement:-Problem Statement-Higher consumption of Diesel in Melting and Preheating of ladles


In Pre Heating Process

Before implementation

Diesel required for Pre Heating -2600 liters

Diesel Cost -2600X47= Rs122200

After implementation

Diesel required for Pre Heating -1170 liters

Diesel Cost -1170X47= Rs54990

Used oil required for Pre Heating -1430 liters

Used oil Cost -1430X15= Rs21450

Energy saving-64.8GJ

Total saving is 33540Rs in every Preheating of Ladles.

Overall benefits in a year 12X33540= Rs. 402480

In Melting Process

Before implementation

Diesel required for Melting -1000 liters

Diesel Cost -1000X47= Rs47,000

After implementation

Diesel required for Melting -540 liters

Diesel Cost -540X47=Rs25380

Used oil required for Melting -660 liters

Used oil Cost- ,660X15= Rs 9900

Energy saving-29.36 GJ

Total saving is 15480Rs in every melting of Ladle.

Overall benefits in a year 12X15480= Rs. 185760 .

Benefits to Organization

Intangible benefit & Uniqueness of project Usage & no discharge used of oil

Value out of waste.

Tangible Benefits


Reduction in Specific water consumption 2.3 m3/MT (FY16) to 1.4 m3/MT (Lowest ever)(FY17)

Designated Consumer under PAT scheme for Aluminum Sector. PAT cycle -1 target over achieved by 0.088

TOE (awarded 22203 EScerts).

CDM project (Emission reduction) is registered with UNFCC w.e.f. 31st Dec-12 and valid till 31st Dec-22.

Implementation of SAP-EHS system

YearGHG emissions (Scope 1 + Scope 2)

in MT CO2 eq.

Metal Volume

(MT)

GHG emissions per Ton

of Al

2014 - 15 6089484 256636 23.7

2015 - 16 6116923 331526 18.5

2016 - 17 8263302 437578 18.9

GHG Inventorisation & Environment Management Initiatives

IMS Year No. of NC No. of Observation Open NC Open Observation

Balco 15-16 3 17 0 0

Balco 16-17 0 10 0 0

Status of EnMS (ISO 50001:2011) Audit Observation


Installed 28 KW Grid connected Solar power plant & Planning for Installation of 5 MW Grid

connected Solar power plant.

Installation of transparent roof sheets & light bottles (liters of light) for harnessing sunlight at day

time inside office buildings, stores and containers to reduce lighting loads during day time has

saved 350 KWh/annum.

Rainwater harvesting is carried out as part of the Company’s commitment towards environment.

Planning to make Green building in township.

Action Plan for Installation of Solar lighting in Area

Utilization of Renewable Energy

SNo. AreaStart of

ProjectEnd of Project

Investment

( In Lakhs )

Payback

(Years)Status

1 Comprehensive Building01.06.2016 31.03.2017

37

28kwp system

installed2 DM Plant 25

3 Lab building

01.04.2017 30.10.2017

10

74 Canteen Plant-2 3

5 HSE office - Plant-1 20

6 Rectifier - Potline-101.11.2017 31.03.2018

257

7 Rectifier - Potline-2 10

Total 96 7


Usage of Emulsion after treatment Qty. – 4320 MT/year.

SPL – SPL detoxification plant set up in under progress by M/s Star Regenerate-N-

Recycle LLP (Korba) and M/s GreenMac Technology Pvt Ltd (Raipur). (First

Company in India to do so)

SPL – Successful trail done for SPL Co-Processing at Ambuja Cement and Ultratech

Cement. Ambuja Cement Received the authorization for Regular Co-processing of

SPL.

)

Waste Management

WASTE TO WEALTH


Green Supply Chain

Sl. No.Name of the

Vendor

Description of the Collaboration / energy reduction

initiative

1 Sumitomo For energy efficient cathodes

2 SGL For energy efficient cathodes

3 GAMI & AP Pot controller upgradation

4 SKF For energy efficient bearing & V-belts

5 GE Pot controller Analytics

6 Metsol For cathode air cooled taps

FY 15 – 183700FY 16 – 102500FY 17 – 87000

Ongoing Plans with Various Vendors

Additional measures for energy

reduction :-

Distribution of 5000no.s Energy booklet

in all schools of BALCO for increasing

awareness towards energy conservation.

Implemented Cardinal rules for energy

savings best operational practices.

Distribution of total-48717 Nos energy

efficient light fittings and fans through

Ujjala Scheme of EESL:-(May-16-June-

16) & (Jan-17 –Apr-17)

PLANTATION DRIVES.No. Initiatives Savings

1 BTAP Capacity Enhancement 396 GJ/Month

2 Bauxite Conversion Ratio 53 GJ/Month

3 Use of Higher Capacity Truck( from 16MT to 25MT) 1697 GJ/Month

4 Use of 12MT instead of 6MT ladles & Energy efficient

engine

116 GJ/Month

5 Use of GPS to identify shortest route

200 GJ/Month

6 Door to Door delivery initiative for issue of material from

stores

7 Transportation of finished goods in Container rake

8 Use of Re-Fuelling Vehicle


Energy savings from Employee & Stakeholder Involvement

Details Unit 2014-15 2015-16 2016-17

FIP Projects No. 5 3 6

QCs / Kaizen Projects No. 25 15 18

Energy Savings Kwh 7664358 4375000 26892304

Benefits due to energy savings Rs. lacs 229 131 806

Vendus Meet to promote Energy Conservation

and Sustainability among Vendors

LED distribution Counter (EESL) at township


ENERGY QUIZ

COMPETITION

ICQCC WINNER -GOLD

Place –Thailand Bangkok

ENERGY QUIZ

COMPETITION

Creating Awareness Among Stakeholders


Title of ProjectName of the

Vendor

Per unit energy consumed%

ImprovementBefore Project After Project

Distribution of energy efficient light fittings

and fans through Ujjala & Pawan Scheme in

Balco township

EESL 72000 Kwh/day 68000 Kwh/day 5.55%

Heater optimization at Himadri Chemicals Himadri - - 9.2%

Implementation of Best Practices

Implementation of Idea generation portal & !DEA@BALCO APP for

generation of idea for All Balco & Contract employees.

Idea generated- 826

Idea implemented- 105

Idea under implementation-206

Initiatives taken by supplier has resulted in energy consumption reduction


Awards and Accolades

Thank You!

Bharat Aluminium Company Limited

Korba, Chhattisgarh

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