Team Hindalco Welcomes You All Energy Efficiency Activities Through Small Groups 1
Team Members 1. Mr. Vivek Agrawal 2. Mr. Anuj Verma 3. Mr. Vivek Kumar 2
Aspect of Energy Saving Ensuring Energy Security. Climate Change Concerns. Statutory requirement like PAT , RPO etc. Methodology By Enhancing energy efficiency. By Energy conservation 3
How is it possible to involve every person of Industry ? By small group In this system , we ensure the participation of each individual for intensive involvement. 4
Organization Structure to involve each individual for improvement APEX COMMITTEE Level 4 WCM SECRETARIAT SETUP IN ALL PLANTS / PLANT SUB Level 3 DEPLOYMENT COMMITTEES COMMITTEES AREA COMMITTEES Level 2 FOR SECTIONS SMALL GROUPS (TEAMS) Level 1 Directly linked to activities or machine 5
Energy Balance sheet World Scenario: Coal : Reserve for 109 years Oil : Reserve for 52.9 years Gas : Reserve for 55.7 years Indian Scenario: Coal : Reserve for 100 years (10% of world production) Oil : Reserve for 17.5 years (0.3% of world production) Gas : Reserve for 33.1 years (0.7% of world production) Source : BP Statistical Review of World - 2013 6
Philosophy In Hindalco all these small group , TQM , TPM etc related activities are being implemented under WCM umbrella . No. of Small Groups : 454 Involvement : 100% Members per small group : 12 to 20 7
Number of Small Group Renukoot Hindalco – Renukoot Total No of Small Group - 454 250 200 150 No 100 50 0 Utilities & Alumina Reduction Fabrication Cogen. Commercial Services 79 206 77 15 28 49 Small Group 8
Case study : 1 9
Selected problem Sump pumps in caustic recovery pit always running in Heat Interchange Department area, while there is no level in the pit . 10
Process Flow diagram Bauxite from Wagon Tippler Mines Hammer Mill Slurry Mix Evaporation Digestion Clarification Clarification HRD Spent Liquor HRD Under Flow (Pregnant Liquor) Drum Filter Compressor Precipitation Red Mud Hydrate (Al 2 O 3 .3H 2 O) Red Mud Disposal Yard Calcination 11 Al 2 O 3 (ALUMINA)
Problem Identification These pumps have been installed Switch in Alumina plant to pump the Manually Operated caustic from pit to the process. To Process Since these pumps are operated Area Hosing Liquor manually therefore these pumps were running continuously after pit being emptied. Hence we lose electrical energy. Therefore we have chosen this project to save electrical energy. 12
Before Improvement / Kaizen 13
Effect of Problem Loss of Electrical Energy Stress in work place Unavailability of Equipment Same Work Again Maintenance of Equipment 14
Target To save Electrical Energy To develop a process to stop idle running hours of sump pumps. 15
Mile stone chart Q.C. – Suprabhat Deptt – Alumina Co-ordinator – R.S.GAUTAM Facilitator – Members Elect.Maint. A.P.Pandey HIRA LAL A.K.SINGH Project :~To Avoid Reasons for selection : Availability of Equipment J.P.SINGH idle running of caustic S.K.SHUKLA recovery sump pump B.R.VERMA K D Yadav Project No. – 1 Start -JAN - 2014 Completed – MAR-2014 T.R.YADAV Meeting – Every K.SINGH ANUJ VERMA Friday Time :~ 4:00 pm – 5:00 R.P.GUPTA pm Target 01 02 03 04 05 6 07 08 09 10 11 12 No. Activity Week 1. Selection of problem 2. Identification of problem 3 . Analysis of the problem 4. Identification of Basic reason 5. Development of Solution 6. Implementation Trials 7. Review & Followup 16
Method Operator (Man) Pump was operated Wastage of Energy manually by Operator had lot of operator jobs to be done at the same time, he may forgot to stop Continuously Idle running of running of sump pump Caustic recovery sump pumps Pump takes over Pumps tripping, Level sensor & hour current & vibration No measuring & breakdown meter were not installed problems of Running hrs since commissioning Machine Materials 17
Reason & Contribution Jan’14 to Mar’14 Freq. % Type Defects Contribution A. 7 70 % No installation of level sensor in caustic recovery pit, hence idle running hours of sump pumps. B. 20% Problem in a cable of sump pump 2 C. 10 % Other reasons 1 18
Pareto- Diagram 100 90 80 70 60 Idle Running Hrs Frequency 50 40 30 20 Cable 10 Problem Others A B C Problems 19
Brain Storming Small Group members have given following suggestions during brain storming session 20
Suggestion # 1 To run sump pump only twice in a shift and stop after empty of pit. Possibility of Human error. X 21
Suggestion # 2 To replace caustic sump pump by air pump to empty the pit. Use of compress air is also costly & wastage of energy. X 22
Suggestion # 3 To install a level sensor in caustic recovery pit which works on auto mode. This is a good suggestion and approved by top management. 23
PDCA Cycle 1. It is informed to section in charge & operation to Suggestion become implement the idea. successful 2.We have modified the drawing to modify the circuit. DO We found that the level Wiring has been done sensor works automatically and it makes the pump off in the panel according when there is no to the drawing. level in the pit 24
After Implementation Auto/Manual In-house ON/OFF Controller built Sensor 25
Comparative study & Effects Suggestion S.No . Implementation 1 Earlier idle running hours It does not happen after of sump pumps was on implementation higher side 2 There was a loss of There is no loss of energy after energy due to idle running installation of level sensor. hours of sump pumps 3 Earlier Electrical There is no problem today. Maintenance work force engagement was more in this case 26
Comparative Study Idle Running Hrs 98.5% 12 Reduction 0.17 27
Comparative Study Energy Consumption 98.58% Reduction in Energy 28
Intangible Gain Ease working Increase in self confidence Release from mental stress. Development of team spirit Safe & Healthy environment 29
Direct profit Sub : Energy Saving by providing Level sensor in caustic recovery sump pump Energy Saving A Details UOM Value Remarks S/ No. 1. New caustic recovery sump pump. (Near HID Gate) 2. TT# 1 West end recovery sump pump. Power Consumption of 6 nos 3. TT# 2 East end recovery sump pump. caustic recovery sump pumps (5 Measured power 4. Old header East end in caustic unloading area. 36.90 1 x 5 )+ (1x20) = 45 HP (Rated in KW 5. Old header West end in caustic unloading area. Power) 6. New header East end in caustic unloading area. 7.Evaporation # 3 area caustic recovery sump pump. 8.Filter Press Area caustic recovery sump pump. Recovery sump pump running 2 hours per days Hr. 12 Sump pumps Running days Days 200 3 Electrical energy Energy Consumed per annum for 4 6 nos.recovery sump pumps KWH / Annum 88,560 saved : 87335 AFTER LEVEL SENSOR INSTALLTION kWh / year Sump Pump Motor running hour 5 per days Hr. 0.17 10 Minutes Sump pumps Running days Days 200 6 Energy Consumed per annum for 7 6 nos recovery sump pumps. KWH / Annum 1,225 Total Energy Saving after the installation of 6 nos Level sensor 8 for 6 nos recovery sump pump per Annum KWH / Annum 87335 Power Saving KW 11 9 Annual Saving Rs. 243,664 Cost of Electrical Energy @ Rs2.79/unit (KWH) 10 Repairing cost Saving B Repairing cost of Pump Rs. 5000 1 Life of pump Days 15 Pump failure starting from October'13. 2 Nos. of pump Nos. 8 3 Annual Saving Rs. 240000 We have consider only 3 months cost of repairing. 4 30 TOTAL SAVING 483,664
Case study : 2 31
smSya pircy boLDr no6 ke 4uk6e toD>ne ke dOran Stemal hone vale Compressed Air ke pt ko smaPt krna | 32
yhI smSya hI Kyo& ? Kyo&ik.. Kyo&ik sme& Compressed Air ka pyog hota hE ijsme& is 10 – 20% Wja hI p/yog layk rhtI hE =eq Wja hI4 v Aavaj ke p me& nQ4 ho jatI hE | Noise : 105 DB 33
Sankey Diagram for Compressed Air System Treatment Generation Approximately Moisture 10% gets to the Dist ribu point of use!! tion Power Consumed by Heat Loss 60% Compressor Delivered Compressed Air Useful Energy 10 - 15% 34
Raw energy to compressed Air conversion process Boiler Coal Turbine (100 MT) ( 85%) 35% Efficiency Generator Sub Station / ( Equi to 35 Transformer Transformer ton ) Cascade efficiency : 77% X Sub Station at User End In Air Compressor - Receiver end (Equi. to 27 ( Utilization 15% - then distribution Equi. to 4.1 Ton ) Ton) transformer 35
Pot room Over view 36
Pot Sectional View ALUMINA HOPPER POT COVERS POINT FEEDERS ANODE RING BUS ALUMINA INSULATION SiC BRICKS DIATHERM 23 FROZEN BATH INSULATION CRUST BRICKS TOE PLATE CATHODE BUS BAR MONOLITHIC PASTE LINING ANODE ANODE (+) (+) MOLTEN CRYOLITE BATH MOLTEN ALUMINIUM MOLTEN METAL CATHODE BLOCK (-) DENSE FIRE BRICKS COLLECTOR BAR CALCIUM SILICATE INSULATION 2 AI 2 O 3 + 3 C 4 AI + 3 CO 2 37
Pot Baking Anode 38
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