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Vedanta aluminium ltd
Vedanta aluminium ltd
Vedanta aluminium ltd
Vedanta aluminium ltd
Vedanta aluminium ltd
Vedanta aluminium ltd
Vedanta aluminium ltd
Vedanta aluminium ltd
Vedanta aluminium ltd
Vedanta aluminium ltd
Vedanta aluminium ltd
Vedanta aluminium ltd
Vedanta aluminium ltd
Vedanta aluminium ltd
Vedanta aluminium ltd
Vedanta aluminium ltd
Vedanta aluminium ltd
Vedanta aluminium ltd
Vedanta aluminium ltd
Vedanta aluminium ltd
Vedanta aluminium ltd
Vedanta aluminium ltd
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Vedanta aluminium ltd

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Vedanta aluminium ltd

Vedanta aluminium ltd

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    • 1. Engineering Excellence Awards 2013 Reduction in Energy Consumption by Implementation of Slotted Anodes Presented By – Vedanta Aluminium Limited |
    • 2. Corporate Overview – Vedanta Aluminium Limited, Jharsuguda  Vedanta Aluminium Ltd is an associate company of the London Stock Exchange listed, FTSE 100 diversified resources group Vedanta Resources Plc. originally incorporated in 2001.  The firm operates a 0.5 MTPA Greenfield Aluminium smelter plant 1 and 1215 MW Captive Power Plant (CPP) supported by highly modern infrastructure at Jharsuguda, Odisha.  In addition to this, construction of 1.2 MTPA Aluminium smelter expansion project at Jharsuguda is going to be commissioned soon.  Rewards and Recognitions –        IMS Certified Plant (QMS-ISO-9001, EMS-ISO:14001 and OHSAS: 18001) Frost & Sullivan’s Green Manufacturing Excellence Awards 2013 "Aspirants Award -Large Business" Received certification for ISO: 50001, Energy Management System. Best HR strategy in line with Business by World HRD congress. Received certification for ISO: 27001 in information Security, Recognized as “Excellent Energy Efficient Unit” at 14th National Award for “Excellence in Energy Management 2013” organized by CII. Third prize in “All Odisha EHS Award 2013” by CII. | 2
    • 3. Vedanta Aluminium Limited, Jharsuguda VISION “We will be the world’s most admired company that consistently defines the leading standards in our businesses, making our stakeholders proud to be associated with us.” MISSION “Our mission is to be a world-class metals and mining group and generate superior financial returns.” | 3
    • 4. Fundamentals Of Hall Heroult Process 1. The amount of substances deposited or dissolved during an electrolytic process is proportional to the quantity of electricity passed through the electrolytic cell. 96485 Coulombs deposit – 1 gm Equivalent of Aluminium 1. One gram equivalent weight of matter is deposited or dissolved on each electrode for 96485 Coulomb (Faraday Constant ) of electricity charge passed through the electrolyte 1 KA in 24 Hrs produces – 8.052 Kg of Aluminium |
    • 5. Raw material Consumption – Production of Aluminium To produce 1 T of aluminium the following amounts of raw materials are needed: 4 T bauxite 2T Alumina Cryolite + 415 Kg Carbon + 20 Kg Aluminium fluoride + 2 Kg + CO2 + + CO + HF + CF4 + Coke + Other gases = 13000 - 15000 kWh Electrical energy 1T Aluminium |
    • 6. Process Flow – Aluminium Production | 6
    • 7. Cost Sensitivity 2980.6 | 7
    • 8. Constituents of Pot Voltage External Voltage Drop 269 mV Clamp Drop 0.2% 8 mV Rod Drop 0.40% 15 mV Transition Joint Drop 0.10% 6 mV Steel Yoke Drop 1.6% 65 mV Stub to Carbon Drop 1.8% 75 mV Anode block Drop Anode Voltage Drop 6.42% 3.80% 161 mV Bath Drop 37.5% 1569 mV Decomposition Drop 40.6% 1700 mV Cathode block drop 7.5% 313 mV Bolt drop 0.2% 8 mV Anode Bath Electrolyte Drop Metal Cathode Cathode Voltage Drop | 8
    • 9. Introduction to Bath Voltage & its components  The bath voltage contains a resistance & an electrochemical part. Components of Bath Voltage •E0 – Reversible Electromotive Force •U Ω – Ohmic Bath Voltage •UBub – Bubble Voltage Bubbles •Anodic concentration Overvoltage •Anodic Reaction Overvoltage Bath •Cathodic Concentration Overvoltage |
    • 10. Reasons for High Voltage drop across the Electrolyte  Anode  During Aluminium smelting, CO2 gases are evolved. CO2 bubbles get accumulated under the anode – forms a high resistance partially insulating film. Increases Energy Consumption Gas accumulation under the anode | 10
    • 11. How to reduce the bubble Drop???  Minimizing bubble drop - most economical way to reduce energy consumption.  Modification of anode surface by Introducing slots can reduce both the bubble drop and anode overvoltage.  Scope of reduction – 50-100 mV CO2 Slotted Anode Slots reduce the bubble resistance by 16-18% CO2 Gas Bubbles | 11
    • 12. Conceptualization & Design Engineering  Anode surface slots were not present in the initial design.  In house design engineering done for appropriate slot height and slope  Straight slots may be a problem in gas evacuation.  Design of experiment and data analysis performed on Slanted slots  Design modifications have been made in the anode forming equipment (Vibrocompactor).  Ensure proper removal of packing coke. Clogging of the slots will lead to excess coke dusting in pots.  In situ Design & Installation of Slot cleaning machine in bake oven. | 12
    • 13. Slotted Anode Trial (Line 1-Section 7)  Trial period – 27th July to 25th Oct  Sample Population – 6.3% of the total operating pots.  Total no. of anodes made for Trial – 5000 nos. Benefit realized • Reduction in Pot Voltage - reduction of 16 mV • Reduction in AEF - Reduction of 0.28 no./pot day. • Reduction in Noise - Reduction of 1.01 mV. • Net saving in Power Consumption of 51.2 kWh/MT. Before Parameters Cycle-1 Cycle-2 24-Aug to 2028-jun to 26-Jul 27-jul to 23-Aug Sep Cycle-3 21-sep to 18Oct Benefit Avg V V 4.257 4.254 4.243 4.241 0.016 AEF No./pot/Day 0.51 0.57 0.46 0.23 0.28 Noise mV 14.79 11.76 12.33 13.78 1.01 |
    • 14. Pot room Parameter Analysis for Slotted Anodes on Full line Implementation Implementation period – 23rd Oct’12 to 13th Jan’13 Benefits observed • Reduction in Pot Voltage - a net reduction of 21 mV. •Net saving in Power Consumption of 67.3 kWh/MT. (36.44 MU/Year) • Increase in productivity – •Current efficiency increase by 1.32%. Volume increase by 20.89 Kg/Day •Amperage Ramp – Net increase of 1.89 KA. Production Volume Increase by 8.6 Kg/Day • Reduction in AEF - 0.15 no./pot day. Total reduction by 46% •Reduction in PFC & CO2 Emissions – Net reduction by 57% in whole pot line. Parameters UOM Before 1st Cycle 2nd Cycle 3rd Cycle Benefit Amperage KA 324 324.2 324.55 325.66 1.66 Avg V V 4.279 4.273 4.268 4.258 0.021 AE Frequency No./Pot/Day 0.32 0.26 0.24 0.18 0.22 Noise mV 17.7 15.8 15.4 13.8 3.9 |
    • 15. Trial & Full Implementation - Impact on Energy consumption Full Implementation of Slotted Anodes Stabilization Period Decrease by 2.23% Impact on Power Consumption (Kwh/MT) Impact on Current ramp Up (KA) Increase by 0.58% | 15
    • 16. Impact on CE  In practice, an electrolytic pot always produces less Aluminium than is as per theoretical (Faraday’s Law) calculation.  Actual CE % = (Actual Production/Theoretical Production)*100 Increase by 1.43% Full Implementation Stabilization | 16
    • 17. Slotted Anodes and Environment – Impact on AEF and PFC Emissions Full Implementation of Slotted Anodes Stabilization Period Reduction by 47% Impact on AE Frequency (No./Pot/Day) Reduction by 57% Impact on PFC Emissions – CF4* and C2F6* (MT/MT of Al) *CF4 (MT/MT) – AEF*AED*0.14, C2F6 (MT/MT) - AEF*AED*0.14/10 (As per universally accepted calculation) | 17
    • 18. Intangible Gains through Slotted Anodes Impact of Slotted anodes  Conservation of non renewable resources of energy.(Coal & Oil)  Total Power Savings by 36.44 MU/Year.  Reduction of CO2 emissions by – 15.26 KT/Yr.  Emissions of green house gases (PFC) reduced by 57%.  Manpower productivity has improved.  Anode effect frequency has been decreased to a large extent productivity has increased.  Elimination of Safety and health hazard  reduced anode effect frequency and immediate auto quenching methods. | 18
    • 19. Way forward - 20 cm deep slot 28 cm deep slot VAL (Press Forming) 207.5,200 mm 575 13.8 days VAL (Slot Cutting) 300,280 mm 575 Reduction of energy by additional 60 Kwh/MT of Al 20 Days | 19
    • 20. | 20
    • 21. Present Performance (Jan’13 – Aug’13) | 21
    • 22. Calculations for CO2 Emissions Savings by Slotted anodes = 67.3 Kwh/T Volume 541593 MT Considering 93.6% CE, 6 3 pots, 326.5 KA. Savings in a yr. = 36449203 Kwh/Yr . 36449.2 Mwh/Yr . Now, 1Mwh = 1000 Units 36449.203 Mwh/Yr. 36449203 = 36.4492 Units MU Now, 1 MU = 1 Gwh As of world standards, The level of the performance standard will be fixed at 420 tonnes of carbon dioxide per gigawatt hour (CO2/GWh). therefore, by implementing Slotted anodes, savings in CO2 Emissions /Yr. will be = 15308.67 T/Yr. = 15.30 KT/Yr. | 22

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