Team Hindalco Welcomes You All Hindalco Industries Limited, Renukoot
Team Member 1. Mr. Anuj Kumar Verma 2. Mr. Vivek Agrawal 2 Hindalco Industries Limited, Renukoot
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 Hindalco Industries Limited, Renukoot
Target Project To increase steam economy of Evaporation Unit II by 0.5 T/T. 4 Hindalco Industries Limited, Renukoot
INDEX Hindalco Renukoot – Profile & Process introduction Background of the Project Concept of the Project Innovation in the Project Project Savings & Economics Challenges faced in implementation Measurement and Verification Potential for Horizontal Application Estimated Life of the Project 5 Hindalco Industries Limited, Renukoot
Hindalco Renukoot : Profile Hindalco, the flagship company of the Aditya Birla Group and industry leader in aluminium and copper has consolidated turnover of US$17 billion & having footprint in 13 countries outside India. Hindalco-Renukoot: Fully integrated Operation Captive Power 800 MW Bauxite Alumina Aluminium Finish Product 6 Hindalco Industries Limited, Renukoot
Alumina Refinery: Renukoot Slurry COAL ASH STORAGE Condensate Steam Power WATER ALUMINA BAUXITE RED MUD Mud Cake REFINERY STORAGE CAUSTIC FURNACE OIL LIME ALUMINA SPECIALITY CHEMICALS 7 Hindalco Industries Limited, Renukoot
Background of the Project : Energy Consumption Trend “Caring for Energy…………….” 8 Hindalco Industries Limited, Renukoot
Background of the Project Steam Bauxite Total Steam Consumption: Flash Tank Slurry Pressure decanter LTD ~250 TPH Unit-II 145 O C Spent Liquor Kelly Press Steam HRD HTD Unit-I 245 O C Precipita- tion DCW HTD Unit- Spent Liquor III Mud To 245 O C washer Calcina- FO tion HTD Unit- IV 245 O C Steam: ~60 TPH Alumina To Evaporation-I smelter Strong Liquor Evaporation-II Evaporation-II Evaporation-III Make Up Caustic Evaporation-IV “Evaporation is essential step in increasing process liquor concentration & maintaining refinery water balance.” 9 Hindalco Industries Limited, Renukoot
Background of the Project Renukoot refinery operates on 4 evaporation units. Evaporation unit-II is the oldest unit among all four with steam economy ~2.92 T/T while Evap-I & newly installed GEA Messo Evap-IV runs on ~3.8 T/T. Steam economy of Evap-II unit has been the perennial problem and could not be solved by several initiatives taken in the past. Liquor flashing unit was installed in May-12 to reduce evaporation load of existing evaporation units. As a consequence one out of two bay of Evaporation unit-II stopped. Performance of evaporation unit is measured by “Steam Economy”. (Evaporation Rate/Steam) 10 Hindalco Industries Limited, Renukoot
Background of the Project Evaporation Unit-II operating with two bays i.e “HID” and “Evaporator” Post liquor flashing Unit installation, “Evaporator” side bay stopped & “HID” side bay kept in operation. Performance with this setups. 11 Hindalco Industries Limited, Renukoot
Concept of the Project Several Brainstorming session held with cross functional teams, subject experts and vendors to improve the Evaporation-II steam economy. There recommendation was to replace existing unit with latest technology energy efficient units ( Expensive option). Fact finding mission was done to explore any stretch in key variables and team arrived at “Is it possible to add additional effects for improving heat recovery thus increase in steam economy?” . To evaluate the viability of the idea and establishing key engineering/process specification, process simulation model developed on SYSCAD software & series of simulations carried out. Various Simulations were carried out to find out no. of optimum effects along with the HID circuit and it emerged that adding 3 nos. effects is techno-feasible solution. 12 Hindalco Industries Limited, Renukoot
Concept of the Project Evaporation-II Phase-II (SYSCAD simulation Results) 07/28/13 18:35:36 Project : Production_Upgradation UMO Case 01 Case 02 Case 03 09Change09FC12 Evap (E:\Ameet SysCAD (with 4 Evap (with 2 (with 3 Work\SysCAD Projects\Final\Production_Upgradation Effect) Base Evap Evap 09Change09FC12 Evap.spf\) Effect) Effect) HID body in line 3 3 3 3 Evaporation Body In line 0 2 3 4 Total Effect In Line 3 5 6 7 Liquor flow to New FF Tak m3/hr 600 600 600 600 Liquor Feed Flow to Evaporation m3/hr 320 320 320 320 O C Liquor Feed Temperature 65.98 65.98 65.98 65.98 Liquor Feed Caustic Conc. gpl 246 246 246 246 O C Liquor Exit Temp From effect Heater to LSH 107.3 111.5 112.9 114.0 O C LSH Htr Exit Temperature 130 130 130 130 Liquor Exit Temp From last effect Flash 91.16 86.57 85.04 83.83 O C chamber (Evaporation Discharge) Liquor Caustic Conc. From last effect Flash gpl 266.0 268.3 269.1 269.7 chamber (Evaporation Discharge) Vacuum on Barometric Condenser mmHg 600 600 600 600 Total vapor load on BC TPH 18.1 17.8 17.6 17.6 Water Required for BC @35 degC m3/hr 482 473 470 471 Water out from BC m3/hr 508 498 488 493 Total duration 4 Weeks (complete flow- Water out Temp from BC deg C 56 56 56 56 sheeting & programming). Total Condansate out m3/hr 38.6 38.7 38.7 38.8 O C Condansate Temp 61.5 61.5 61.5 61.5 No. of Simulation Run i.e. 20 ( with different setups/combinations (including Total Evaporation Rate (Evap+FFTk) TPH 33.2 35.9 36.7 37.4 Toatl steam Consumption TPH 15.7 12.8 11.8 11.0 Base case). Steam Economy T/T 2.12 2.81 3.11 3.39 Case no. 2 (i.e. 3 nos. Evaporator effects in line with the HID circuit) was selected for modification and implementation in the area 13 Hindalco Industries Limited, Renukoot
Innovation in Project Evaporation Unit # 2 New Scheme ( HID side with Add. Effects in Operation – Phase II Engineering done to feed input stream from evaporator side instead of earlier arrangement of HID side. This resulted into: - Lower pressure drop because of its configuration (~1.1 Kg/cm2) - Improved heat recovery as bigger Heat transfer area effects (i.e. HID effects) at highest temperature end. 14 Hindalco Industries Limited, Renukoot
Innovation in Project Evaporation Unit # 2 New Scheme ( HID side with Add. Effects in Operation – Phase II Another major challenge was vacuum system for evaporator effects with this configuration: - Evaporator side vacuum system can not be taken in line due to conflicting configuration. - Possibility was worked out to utilized HID side vacuum circuit, technical feasibility worked out and found suitable & implemented . 15 Hindalco Industries Limited, Renukoot
Innovation in Project Evaporation Unit # 2 New Scheme ( HID side with Add. Effects in Operation – Phase II Another area requiring engineering modifications was flexibility to revert in old configuration as during rainy season evaporation load may increase. Facility implemented with suitable provisions. 16 Hindalco Industries Limited, Renukoot
Saving Achieved 17 Hindalco Industries Limited, Renukoot
Saving Achieved Saving realization after Project completion Before After Total Diff S # Parameters UMO Dec-12 to Apr-14 May-14 to May- (After- Before) 15 Steam Economy 1 t/t 2.95 3.42 0.47 Steam Consumption 2 TPH 13.4 10.9 -2.46 O C 3 LSH Temperature 130 130 0.06 4 Evaporation Flow m3/hr 315 325 9.65 Power Saving: Pumps Running (Nos.) Pumps Motor, HP Pumps Pump Nos./HP Before After Before After 2 * 60 HP VT pumps 3 NIL 310 0 2 * 125 HP Circulation Pump 270 + 250 HP 1 1 270 270 Discharge pump 1 * 40 HP 1 1 40 40 FF Tk. (N) Feed pump 2 * 75 HP 1 1 75 75 HID Feed Pump 2 * 215 HP 1 1 215 215 PLD Pump 2 * 40 HP 1 1 40 40 HID cond. Pump 2 * 10 HP 1 1 10 10 Evap cond. Pump 2 * 20 HP 1 1 20 20 IWR pumps 3 * 180 HP 3 2 540 360 Total 13 9 1520 1030 Power Savings (Before - After), HP (Motor loading assumed 85 %) 417 Power Savings (Before - After), KW 311 18 Hindalco Industries Limited, Renukoot
Project Economics A. Investment: Size Cost S # Item Quantity Rs (lacs) (Rs/Unit) Dia Length, mtr 1 Sh-40 Pipe 12" 50 3520 1.76 2 Sh-40 Pipe 10" 40 3433 1.37 3 T/F flange 12" 10 1236 0.12 4 T/F flange 10" 10 1236 0.12 5 Pipe Fabrication and Erection cost 12" 50 325.4 0.16 6 Pipe Fabrication and Erection cost 10" 40 271.8 0.11 7 Miscellaneous 0.10 Total Investment in Rs Lacs 3.75 Total Investment in $ ( 1 $ = 66.30 Rs as on 01-01-2016) $5,659 B. Steam Saving Acquired Steam Saving (Saving for 10 1 2.46 TPH 890 157.9 months from May-14 to May-15) Total Saving in MTOE 1467 Total saving in $ ( @ 300 USD / MTOE) $4,40,100 C. Power Saving Acquired Power Saving (For 275 days per year) 310.71 KW 2.89 59.3 1 Total Saving in MTOE 176.36 Total saving in $ ( @ 300 USD / MTOE) 52908 Total Saving ( B + C ), $ USD/Annum $4,93,008 4.0 Pay Back Period (Days) 19 Hindalco Industries Limited, Renukoot
Challenges Faced in Implementation Space constraint Congested Layout of the unit Flexibility to revert on earlier configuration. Cost economics 20 Hindalco Industries Limited, Renukoot
Recommend
More recommend
