Team Hindalco Welcomes You All Hindalco Industries Limited, Renukoot
Team Introduction Vibhav Upadhyay Anuj Verma Vivek Agrawal 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 Hindalco Industries Limited, 3 Renukoot
Project Theme To Reduce Pot Voltage at Renukut Smelter to Enhance Energy Efficiency 4 16 Nov 2016
INDEX Hindalco Renukoot – Profile & Process introduction Background of the Project Concept of the Project Root cause Analysis and Approach adopted Project Savings & Economics Challenges faced in implementation Measurement and Verification Hindalco Industries Limited, 5 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. It is fully integrated plant. Hindalco Industries Limited, 6 Renukoot
Hindalco Renukoot : Fully Integrated Operations Captive Power Bauxite Alumina Finish Product Aluminium THROUGH 7
Typical Cost of Aluminium Production wages 5% Smelter Power 40% Alumina 35% Store, potlini ng, misc. 4% Depriciation Net carbon AlF3 1% 15% 1% 8
Renukut Smelter • Renukut smelter has 11 pot lines and 2138 Electrolytic cells (pots). Annual Aluminum Production is 409 KT. 9
Process Description 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 ANODE ANODE (+) (+) LINING MOLTEN CRYOLITE BATH MOLTEN ALUMINIUM MOLTEN METAL CATHODE BLOCK (-) DENSE FIRE COLLECTOR BRICKS BAR CALCIUM SILICATE INSULATION 2 AI 2 O 3 + 3 C 4 AI + 3 CO 2 According to Faraday’s Law: Production = 8.052* Amperage*Current Efficiency 10
Project background V CE • Power Consumption kWh kg / 298 Pot voltage, V 4.540 4.520 4.500 4.480 4.460 4.440 4.420 This project was taken to reduce pot voltage by 80 mv 11
Problem Diagnosis 12
Project Scoping 13
Approach Project Methodology: Statistical analysis of process parameter Stability Test ( Run Chart) Process Capability Gage R & R Study Micro mapping & Process Mapping Regression Analysis Cause and effect analysis 14
Macro Map • Primary alumina from Alumina • DC Power from Rectifier • Anodes from carbon plant • Secondary alumina through DSS plant Alumina Feeding Pot Lining Pot baking Pot Loading -Installation of point -New pot shell -Pot taken -Pot taken in feeders and Micro -Refractory lining in circuit operation Processor control -Corrections Sampling -Bath ratio balance Metal Tapping -Bath ratio, temperature by adding AlF3 or -Metal tap out in - Bath Level Soda ash cruce measurement - Bath maintenance Anode changing Crust breaking -Spent anode removal Bath maintenance -Crust breaking Dust skimming - Solid bath addition - Bath melting -New anode set 15 - Anode covering
Fish Bone Diagram Team did round of brainstorming sessions to identify all potential causes using fishbone diagram. Total 18 X’s identified which further reduced to 10 using C&I matrix 16
Critical parameters ACD Cathode Voltage drop Pot age Noise Alumina concentration Metal level Anode effect Bath Chemistry Clamp drop Diamond drop 17
Regression Analysis Correlation & regression analysis carried out to find out most critical parameters 18
Regression Analysis • Series of DOE were carried out to find out the way to reach at optimum pot voltage without affecting other critical parameters. •A Solution Selection Matrix prepared to prioritize the solution and different DOE (Design of Experiments) conducted. Finally an action plan made to reduce pot voltage. . Pot age ,ACD ,Noise ,CVD, Bath Chemistry 19
Problem Remedy 20
Problem Remedy Voltage Reduction Plan Noise 1. Noise limit for voltage reduction – Avg. noise value 0.002V/pot 2. Voltage will be reduced @ 0.01V/pot only Age 1. Minimum voltage of 4.27 V with life 90 to <3000days. 2. High life (>3000 days) voltage 4.36 V(min) 3. New pot maintained upto 4.320 V/pot by 90 days of life. 21
Problem Remedy CVD 1. Voltage of pots with high CVD is 4.35 (min) Bath Chemistry 1. Bath Ratio target increased from 1.130 to 1.160 due to higher CaF2 content in bath 2. Maximum 0.06 V reduction in one week ACD 1. No voltage reduction if pot is under high noise, low bath level, metal left in the pot, and less current anodes 22
Control Plan 23
Control plan for Improvement Monitoring parameters • Metal Left • High bath temperature Pots. • High Bath Ratio Pots. • Low Bath Level Pots. • Anode Effect frequency. • High search time ( higher Alumina content in bath) pots. • Avg. Noise of the lines and No. of noisy pots. • No. of pot failure Monitoring of all these parameters and strategy change in between whenever deviations found. 24
Replication • Formation of Standard Operating Practices. • Extended trial in all pot lines before implementation • Implemented in all pot lines • An exhaustive monitoring system developed • Any deviations were planned to be rectified within 8 hrs 25
Results 26
Tangible Results Pot voltage Volts/pot July'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15 Jan'201 Feb'16 Mar'16 6 Pot voltage 4.515 4.513 4.479 4.470 4.453 4.448 4.450 4.444 4.442 Strict follow up of action plan led to reduction in pot voltage 27
Tangible Results • Improvement in CTQ Pot voltage 4.540 4.520 4.500 Volts/pot 4.480 4.460 4.440 4.420 4.400 July'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15 Jan'2016 Feb'16 Mar'16 28
Tangible Results • Improvement in Power consumption Power, kWh/T 14300 14250 14200 14150 14100 14050 14000 13950 13900 13850 13800 July'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15 Jan'2016 Feb'16 Mar'16 29
Tangible Results Power consumption reduced by 284 kWh/ T 30
Intangible Results • Enhance in process consistency also improved metal purity • Lowest Iron content and Silicon content in aluminium. • Increased Internal customer satisfaction 31
Thank You 32
Recommend
More recommend
