national award for excellence in energy management - 2017...

National Award for Excellence in Energy Management - 2017

Sterlite Copper, Tuticorin, Tamilnadu

1

First private sector Copper Smelter in India with

integrated operations extending from mines in Australia

to smelter, refinery and rod plants in India

Sterlite Copper produces approx. 2% of world copper

production and holds 36% of market share in India

Revenue in excess of Rs. 19,000Cr & 3rd largest

company in Tamil Nadu contributing to 3% of TN GSDP.

World first custom copper smelter with Zero liquid

discharge system since the inception of plant.

An ISO 9001:2008, ISO 14001:2004, OHSAS

18001:2007, ISO 17025:2005,ISO 50001:2011 and ISO

27001:2005 accredited organization.

World first certified mining & metal company in

Asset management System ISO 55001:2014

Employment to 2800 directly and 2,0000 indirectly

Largest private sector user of port; contributes to 8% of

port’s revenue.3

Marching Ahead with Pride

CAPACITY SUMMARY

THOOTHUKUDI COMPLEX

SILVASSA COMPLEX

Product Capacity (TPA)

Copper Anode 4,00,000

Copper Cathode 4,00,000

Copper Rod 2,50,000

Power 160 MWParticularsCapacity

(TPA)

Refinery 1,95,000

Rod Mill 1,60,000

Thoothukudi

SilvassaParticulars Capacity (TPA)

Smelter 4,00,000

Refinery 2,05,000

Rod Mill 90,000

Sulphuric Acid 13,00,000

Phosphoric Acid 2,30,000

Power 160 MW

Gypsum 12,00,000

Ferro Sand 8,00,000

5

Energy Management

@ Sterlite Copper

6

Plant wise – Break up Energy wise – Break up

Power60%

FO17%

HSD0.1%

Petcoke17%

LPG3.8%

LNG0.1%

Steam2%SMLT

46%

SAP11%

PAP10%

Refinery21%

CCR10%

ACP2%

7

UOM: GJ/MT of Cathode

2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16

Note: SEC Values are inclusive of all Units in Sterlite Copper Business

2016-17

0

2

4

6

8

10

12

2008-2009 2009-2010 2010-2011 2011-2012 2012-2013 2013-2014 2014-2015 2015-2016 2016-17 2017-18

11.88 11.69 11.24 10.93

8.42 8.84 8.3 8.2 7.96 7.5

2017-18 Projected

2008-09

8*(Source : Brook Hunt 2015)

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

16.00

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(ISA

)

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(Re

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4.07 4.44 4.94 5.19

7.13

8.62 9.03 9.58

13.33

15.02

GJ/MT of Anode

9

GJ/

MT

of

An

od

e

Way forward

5.194.8 4.07

0.2 0.1 0.04 0.01 0.01 0.01 0.690.01 0.01 0.04

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11

6 6

9 108

11

5

108

454

17 89 5595

700

100

200

300

400

500

0

5

10

15

2011-2012 2012-2013 2013-2014 2014-2015 2015-2016 2016-2017 2017-2018

Energy Projects Implemented

No of Projects Total Savings

5

20 19

12 12

6 40

5052

0

10

20

30

40

50

60

0

5

10

15

20

25

Water & Environment Projects Implemented

No of Projects Total Savings

Total Savings Rs.1001 MillionsTotal Power Savings 212.6

Millions Units,Total Water Saving of 0.19

Million m319869MKCAL and Reduction of

0.19Millions tons of C02

Savings in Millions rupees

Totally 28 Projects were Zero fund investment projects

12

3.33.5

2.9

3.63.8

4.0

4.6

1.89 1.93

1.30

2.00 2.05 2.09 1.94

11.2

18.0

23.8

41.16

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

40.0

45.0

50.0

2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 FY 2020

Cathode in Lacs Mt GHG per MTProduction increase in % (Baseline FY12) GHG increase in %

In line with COP21 meet in Dec 2015 Sterlite copper has taken an Co2 Emission reduction initiative to achieve 20% reduction by 2020 from the year 2012.

13

Innovative Projects

1. Oxygen Plant TSA Power Optimization

2. Optimization of Pet coke Consumption.

3.Refinery Current Efficiency (CE) Improvement from 97.92% to 98.5%

4. Electric FO Pre-heaters modification to Steam based Heaters

5. Reducing the over all anode rejection rate from 4% to 2%

6. Increasing Cast wheel operation MTBF

14

15

SCF - 2 Units

Conveying System

GranulationTo Discard

OXYGENPLANT

Converters

4 Units

RHF-2 Units

Ware House

Anode Furnace

3 Units

Twin CasterAnode Stacking

6 Concentrate Bins

7 Flux Bins

Lance

ESPWHRB

SAP

Loader

Anodes to Refinery

Granulation

To Discard

Project Area

Copper Concentrate

Oxygen Plant in Sterlite Copper uses the Gas Separation System through Temperature Swing Adsorption(TSA) technique. The atmospheric air is passed to adsorbent with high Nitrogen affinity at lower temperature for a specified period to adsorb Nitrogen in air. Pure Oxygen is received through the Gas separation column for further processing. At a certain point the adsorbent is saturated and regeneration by desorption is required. For this the temperature is raised to 240 oC to desorb the adsorbed components ,the set point has been optimized to 200oC which is sufficient for the process.

17

Power 800units/day

GHG Emission 238MT / Annum

CostImpact

Rs.12.88Lacs/Annum

PARAMETERS SAVINGS

Zero fund Investment

18







19

SCF - 2 Units

Conveying System

GranulationTo Discard

OXYGENPLANT

Converters

4 Units

RHF-2 Units

Ware House

Anode Furnace

3 Units

Twin CasterAnode Stacking

6 Concentrate Bins

7 Flux Bins

Lance

ESPWHRB

SAP

Loader

Anodes to Refinery

Granulation

To Discard

Project Area

Copper Concentrate

20

LA

NC

E ISA furnace

Pet coke is used in ISA smelting furnace in order to increase the energy level in the furnace.

Pet coke is consumed due to two different reasons, primarily to increase the energy level in the blend and also consumed when the high volume of reverts treated in furnace.

Revert is a material, formed due to

solidification of liquid Matte/Blister

during its transfer.

Before this project revert generation was

280MT/day after implementation it

reduced to 180MT/day.

21

Net Saving Rs

10.33 Millions

P.A

Zero fund Investment

41450:Unit of Power Saving

41450

1394 Tons of Pet coke consumption

reduction

1394

Co2e: Reduction of 3832.80T

3832.8

22







23

HeatExchangers

Polishing Filter

Circulation Pump

Circulation Tank Decant Tank

Head Tank Reagent

Dosing

Tank

Electro refining Cell

Cu Anodes + SS Plate Cathodes +

Electro-refining : Cu Deposit

Glue Addition

Smooth Deposit

Current 35kA

Less Resistance!! Lesser Power!!!!

Optimized glue(11080gpl)

24

Refinery Process and Importance of Current Efficiency

Electro-refining of Copper(Cu) from 99.7% Cu anode to 99.99% Cu cathode is driven through Electrolysis reaction by using DC power through rectifiers. The ratio of actual copper deposit obtained as product to the theoretical deposit calculated as per Faraday’ law is measured as a Key indicator of process called Current Efficiency (CE%). Physical characteristics of electrode and chemical characteristics of anode and circulation electrolyte temperature & impurities(soluble & insoluble) are factors affecting CE.Continuous Improvement project taken by Refinery team to increase the CE from current level of 97.92% to 98.5% and achieved by correction of verticality of SS Cathode plates, Anode verticality control through anode lug mill angle correction, introduction of verticality measurement tools and electrolyte insoluble impurity control by 100% decant volume filtration in circulation

25

Power cost

• Reduction in power due to reduction in Power consumption (60000units/Year) - Rs 2.8 lacs/annum

Extra cathode production

• Due to increase in Current efficiency by 0.4% 600 MT of cathode will be produced per annum - Rs 38.56 lacs/annum

Overall savings

•Overall savings – Rs 41.36 Lakhs/annum Zero fund Investment

27

DAILY

•Separate report on energyand water consumption.•Utility portal to track theenergy & water information

•Monitoring energy & waterconsumption on daily basisin WAR Rooms and Trackingin MII

• Reporting the major variancesto the management

•Review of concerns raisedby energy manager in dailymorning meetings

Utility

Energy Manager

EnergyManager

Head Production

FREQUENCY REPORTS/SYSTEM RESPONSIBILITY

Monthly

EnergyManager

CEO

EnergyManager

CEO, EXCO,

Corp HSE

MIS reporting (Area wise) forenergy & water consumption forthe whole plant

Review on projects related toreduction in specific energy &water consumption

Variance analysis with respect tobudgeted quantity

Monthly review on specific energy& Water consumption

Effective monitoring of pipe lineassets through SAP R/3 Linearasset management.

28

ENERGY TRACKING

POWER TRACKING

29

WATER TRACKING

UTILITES TRACKING

30

Energy Management

System ISO 50001:2011

P

A D

C

Analyze past energy use and consumption

Identify areas of significant energy use

Setting energy baseline

Identify objectives, targets and action plan

Competence and training

Communication

Operational control and design

Monitoring, measurement and analysis

Regular internal audits

Raising non conformities

Corrective and Preventive Actions

Monitoring the performance

Parallel deployment

ENERGY MANAGER

SMELTER EC

SAP & PAP EC

PURCHASE & Finance

EC

REFINERY EC

CCREC

PMBEC

ELECTRICALEC

MECHANICAL EC

EC – Energy Coordinator

33

Hazardous waste

Type Method of Disposal / Usage

ETP cakeStored in Secured Landfill

FacilityScrubber Cake

Spent Catalyst

ESP / Gas Cooler/

WHRB Dust

Recycled by Pneumatic dust

conveyor in Smelter

Spent Oil

Sold to CPCB registered

recyclers

Oil Sludge

Copper Scrap with

copper sulphate SLF Construction

Copper Slag Road

Non- Hazardous Waste

Type Method of Disposal/Usage

Copper Slag

Land filling application / Cement /

Concrete / Abrasive / Road building /

alternative to river sand

Gypsum

Sale to Cement Industry for cement

manufacturing /fertilizers and bricks,

Gypsum boards in construction

industry

Lime grit Sale to detergent industries

Garbage Organic Convertor/Recyclers

34

Sterlite Copper is using the Solar PV for Lighting systems of 4000units/Year

Planned to Set up a Floating Solar Power Plant on the water reservoir capacity of 1 MW in this current year & 40MWp Solar plant in the 300 acres

within the year of 2020.

Waste Heat generated out of process has been recovered with WHRB to generate steam which has been utilized for process heating & to generate

power. Last four years 531.76 lacs units has been generated.

Sterlite Copper Purchased 13092 Solar & 30486 non Solar REC certificates as per RPO/SPO purchase obligation

Socio-Economic

Eco-efficiency

SUSTAINABILITYEnvironment

Economic

SocialSocio-Environment

Safety & HealthEnvironmental RegulationsGlobal Climate ChangeAccess to potable waterCrisis ManagementEnvironmental Justice

Clean Air, Water & LandEmissions ReductionZero WasteBiodiversity

Resource EfficiencyProduct StewardshipLife cycle managementReduced carbon/Environmental foot print

InnovationCapital Efficiency, Risk ManagementMargin Management, Growth EnhancementShare holder returns

Jobs CreationSkills EnhancementSocial investmentsSecurityBusiness Ethics

DiversityHuman RightsCommunity RelationsIndigenous peopleCultural heritageLabor Relations

Material risks identification & management

Stakeholder engagement & Grievance management

Incident investigation & Corrective, Preventive Action Management

Code of Conduct, Anti-Bribery and Human Rights

Contractors Safety Management

Environmental Management

Safety Management

Management of Change

Community Relations

Supplier & Vendor Management

Transportation & Logistics Management

0

2

4

6

8

10

12

14

Yes No Yes No Yes No Yes No Yes No Yes No

ISO 9001 ISO 14001 OSHAS 18001 Renewable Energy

Consumption

Plans to replace ozone

depleting susbstances

Plans to reduce GHG

emissions

7 6 5

8

5

8

5

8

3

14

7

10

Category: Raw Materials

012345678

Yes No Yes No Yes No Yes No NA Yes No Yes No

ISO 9001 ISO 14001 OSHAS 18001

Renewable Energy Consumption

Plans to replace ozone

depleting susbstances

Plans to reduce GHG

emissions

7

24 5 4 5

3 42 1

8

3

6

Category: Spares and Consumables

Opportunities:

• Can initiate Vendor/Supplier certification systems

• Carry out energy audits for energy efficiency & conservation

• Partnership with vendors for energy service contracts.

• Training and development

39

Business Partners

Implementing Project

PurchasePolicy

Vendor Data Base

Reward& Recognition

Training & Awareness

Sustainable Development

Implementing Projects:

organizing Projects on Energy & water

Resourcing skills and numbers

Result Tracking and Sustain the KPIsReward& Recognition

Building Business case and ownership

Measurement, baseline and KPIs

Cost tracking

Benefits tracking and rewarding

Training & Awareness:

Regular Training and Awareness on Sustainable Energy & water Conservation

Progress monitoring, reporting & Help to Improve

Policy:

Making Policy for Energy Efficiency Product purchase

Priority to the Energy Efficient Products in the negotiations

Monitoring and reporting deviation

Vendor Data Base:

Clear and agreed scope on Energy Policy during vendor registration Process

Dependency Energy management

Sustainable Development: Stake Holders are

Encouraged toward Green Energy

Auditing the vendors & suppliers on sustainable front(>20 vendors Audited)

Total 21 Major Projects

implemented by Business

partners Which Resulted

in saving of Rs 145 Lacs

41

Planned to set up 10MLD sewage treatment plant by using the sewage from the tuticorin township by 2018.

Exploring the market for selling the Hazardous waste generated from ETP instead of dumping in SLF

Setting up desalination plant with 10MLD capacity for plant process purpose as well as for local communities by 2020.

10% reduction of absolute power & water consumption from current level by this financial year .

20% GHG emission reduction by 2020.

43

Employees & Business Partners

National Energy Conservation week celebration with

pledges and awareness program for contract and

company staffs.

Circulating energy conservation related article across

the plant through mail

Displaying energy conservation posters in desktops.

Distributed LED lights to employees and local

communities

Cross word puzzle on energy conservation for the

employees

Distributed the energy awareness pen to all the

employees & contractors

Creating awareness through using the common

vehicle for transportation.

ENERGY DAY CELEBRATION

LED Distribution

Energy Awareness Pen

44

Best Energy Conservation ideas competition

Employee’s innovative ideas are posted on line in

Kaizen@sterlite database

Energy Awareness stickers across the plant area

Energy Awareness Wall painting in the plant

premises

Community

National Energy Conservation day has been celebrated

in the nearby villages and awareness session has been

given to community people regarding energy

conservation.

Conducted painting competition related to energy

conservation for school children in the local community.

Energy Awareness @ Schools

Energy Awareness Sticker

Energy Awareness Wall painting

45

LETS GO GREEN

national award for excellence in energy management - 2017...

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