Qualtech 2009


Published on

Published in: Business, Technology
1 Like
  • Be the first to comment

No Downloads
Total views
On SlideShare
From Embeds
Number of Embeds
Embeds 0
No embeds

No notes for slide

Qualtech 2009

  1. 1. 2009<br />17th- 18th Sep&apos;09, Taj Presidency, Mumbai<br />Day 1: IMPROVEMENT<br />Project Title<br />Improvement at Alumina Refinery Renukoot - Capacity Enhancement of Vanadium sludge by-product through process improvement <br />Company<br />Hindalco Industries Limited, Renukoot (Alumina Plant) <br />Presenter<br />Vikas sarolia<br />
  2. 2. Team Members<br />
  3. 3. Hindalco<br />A Flagship Company of Aditya Birla Group<br />India’s largest Aluminium producer with a capacity of 4,45000 MTPA<br />
  4. 4. Vision <br />Hindalco Vision<br />To be a premium metals major, global in size and reach, with a passion for excellence.<br />Alumina Plant Vision<br />To supply reduction grade alumina to our smelter at minimum possible cost <br />
  5. 5. Mission<br />Hindalco Mission<br />To relentlessly pursue the creation of superior shareholder value by exceeding customer expectations profitably, unleashing employee potential and being a responsible corporate citizen adhering to our values.<br />Alumina Plant Mission<br />To pursue the creation of value for our stakeholder by producing world class alumina and maintaining harmony with the environment<br />
  6. 6. Our Values<br /><ul><li>Integrity</li></ul>Honesty in every action.<br /><ul><li>Commitment</li></ul>On the foundation of integrity, doing whatever it takes to deliver, as promised.<br /><ul><li>Passion</li></ul>Missionary zeal arising out of an emotional engagement with work.<br /><ul><li>Seamlessness</li></ul>Thinking and working together across functional silos, hierarchy levels, businesses and geographies.<br /><ul><li>Speed</li></ul>Responding to stakeholders with a sense of urgency.<br />
  7. 7. Hindalco - Renukoot<br />Production <br />volume<br />
  8. 8. Fully Integrated Operations <br />Captive Power<br />Finish Product<br />Bayer Process<br />Electrolysis<br />
  9. 9. Alumina Refinery View <br />
  10. 10. Refinery At A Glance<br />Alumina : 720,000 MT/annum<br />Raw Materials : Bauxite, Caustic,<br />Steam,Power,Furnace Oil<br />Product : Alumina<br />By Product : Vanadium Sludge<br />
  11. 11. Alumina Refinery Process<br />MUD Cake<br />INPUTS:-Hot Water Filter Cloth Lime Starch Flocculant<br />INPUTS:-Steam,<br />Bauxite, Caustic<br />DIGESTION<br />CLARIFICATION<br />Condensate to Boiler & Process<br />BAYERS<br />CYCLE FOR<br />INPUTS:-CGM<br />ALUMINA<br />INPUTS:-fuel Oil<br />PRECIPITATION<br />INPUTS:-Steam<br />EVAPORATION<br />Al2O3.3H2O<br />CALCINATION<br />Vanadium Plant<br />Alumina<br />Vanadium Sludge<br />
  12. 12. Essence of the project<br /><ul><li> Bauxite contains around 0.26 % vanadium pentaoxide
  13. 13. Vanadium ingresses into the process liquor during the Digestion process as an impurity
  14. 14. Vanadium precipitates along with the hydrate,
  15. 15. Impacts Alumina quality
  16. 16. Causes scaling problem</li></li></ul><li>Essence of the project<br />High vanadium content in alumina reduces the current efficiency of alumina smelting and impacts the metal purity<br />
  17. 17. Essence of the project<br />Vanadium impurity removal is a challenge with the everlasting pressure for Alumina production enhancement <br />
  18. 18. Essence of the project<br /><ul><li> Increased vanadium content in bauxite (from 0.16% to 0.26 % ) has further intensified the challenge
  19. 19. Existing Vanadium Plant capacity proved inadequate</li></li></ul><li>HINDALCO INDUSTRIES LIMITED <br />ALUMINA PLANT - VANADIUM SLUDGE PLANT PROCESS FLOW SHEET<br />C - 260 GPL<br />0<br />0<br />Temp - 60<br /> C<br />Temp - 35 <br />C<br />V2O5 - 0.60 GPL<br />THICKNER <br />TANK<br />W<br />J<br />W<br />J<br />A<br />A<br />A<br />A<br />COLD <br />TO HOMO TANK<br />CHILLED<br />T<br />C<br />T<br />C<br />LIQUOR <br />LIQUOR <br />E<br />K<br />E<br />K<br />TANK<br />TANK<br />R<br />E<br />R<br />E<br />T<br />T<br />C - 270 GPL<br />0<br />EVAPORATION <br />Temp - 70<br /> C<br />V2O5 - 3.25 GPL<br />Flow - 475 LPM<br />EXIT LIQUOR<br />WATER FROM COOLING TOWER<br />CHILLED WATER FROM REFRIGRATION UNIT<br />VANADIUM <br />SLUDGE CAKE<br />SLURRY FEED <br />% V2O5 - 15.0<br />TANK<br />% Na2O - 25.0<br />% Al2O3 - 7.0 <br />FILTRATE<br />Schematic Diagram Vanadium Plant (Before)<br />P<br />H<br />E<br />
  20. 20. Arrival to solution<br /><ul><li>Detailed vanadium balance applied on Alumina Refinery
  21. 21. Brain storming sessions done with cross disciplinary experts
  22. 22. Common conclusion to purge out the vanadium by enhancing vanadium sludge removal rate</li></li></ul><li>Arrival to solution<br /><ul><li>Several DOE performed on lab and on pilot plant to test hypothesis
  23. 23. A thorough investigation with regard to the data collection for the period (last 12 months) done, Subsequently, estimates carried out to evaluate the possible increase in the production.</li></li></ul><li>Bottlenecks<br /><ul><li>The inherent inefficiency to yield maximum production due to process being batch in nature
  24. 24. Maximum 10-12 batch per day resulting liquor processed 500-600 m3/day only
  25. 25. Vanadium concentration in the liquor also impacting the sludge extraction</li></li></ul><li>Bottlenecks<br /><ul><li>Higher initial liquor temperature
  26. 26. Lower flow handling capability
  27. 27. Frequent inflow reduction due to less cooling owing to scaling on tanks & piping of vanadium plant</li></li></ul><li>Course of action<br />The inherent inefficiency to yield maximum production due to process being batch in nature<br />Action Taken<br /><ul><li> Thorough piping modification carried out to convert existing process from batch to continuous
  28. 28. Effective volumetric flow handling capacity increased</li></li></ul><li>Course of action<br /><ul><li> Vanadium concentration in the liquor also impacting the sludge extraction
  29. 29. Higher initial liquor temperature</li></ul>Action Taken<br /><ul><li> Philosophical change made to take evaporation exit liquor in place of inlet liquor
  30. 30. The above has also facilitated in making vanadium inlet liquor at lower temperature (67 in place of 80deg C)</li></li></ul><li>Course of action<br />Lower flow handling capability<br />Action Taken<br /><ul><li> Upgraded the tank volumes and pumping capacity </li></ul>( 500 lpm to 1000 lpm)<br /><ul><li> Operating philosophy shifted from low volume low temperature to high volume high temperature after several DOEs at laboratory scale</li></li></ul><li>Course of action<br />Frequent inflow reduction due to less cooling owing to scaling on tanks & piping of vanadium plant<br />Action Taken<br /><ul><li> Lab studies carried to find out best alternative to remove these scales
  31. 31. Innovative idea to circulate hot spent liquor stream (900C) proved to be best alternative to dissolve these scales</li></li></ul><li>Significant achievements<br />Increased vanadium sludge production by 47% <br />(4228 MT in FY09 against 2875 MT in FY08) <br />
  32. 32. Significant achievements<br />Vanadium Sludge Production<br />
  33. 33. Significant achievements<br />Tangible gain of the project <br />Vanadium sludge production exceeded <br />by 1352.60 MT in FY09 <br />Which lead to extra revenue generation of <br />Rs 1729 lacs in FY09<br />
  34. 34. Significant achievements<br />Reduced vanadium concentration in process liquor (From 3.10 gpl to 2.88 gpl in Fy09)<br />
  35. 35. Significant achievements<br />Alumina Product quality w.r.t. vanadium has been maintained less than 0.004 % in spite of increased vanadium level in liquor<br />
  36. 36. Vanadium Sludge Production<br />
  37. 37. Plans for Sustainability<br />Scheduled lab analysis for stringent monitoring of the liquor characteristics and change in nature of the liquor for proactive decision making.<br />
  38. 38. Plans for Sustainability<br />Electronic Instrumentation for monitoring and controlling the key process parameters provided for process and quality control<br />
  39. 39. Plans for Sustainability<br />Weekly Hot spent liquor circulation schedule prepared with proper SOP and maintained<br />
  40. 40. Contribution of Team Members<br />Beyond the Call of Duty<br /><ul><li>Brain storming and review sessions beyond duty hours.
  41. 41. Shift-wise chasing of related agencies for proper execution and in time completion of job apart from existing KRAs and routine responsibilities
  42. 42. Off time trials on equipment for quality assurance of product.</li></li></ul><li>Key Learning&apos;s<br />The entire Renukoot team demonstrated that it is ever ready to accept challenging tasks at all times with the spirit of team work and as a Hindalco family in the hour of crisis and also innovate and develop through learning’s to mitigate constraints. <br />The Key learning’s can be summarized in the following points :<br /><ul><li>Planning and Organizing
  43. 43. Meeting Challenges head on
  44. 44. Thinking out of the Box
  45. 45. Development of multiple sources for key inputs
  46. 46. The focus and belief of the manufacturing team that any development on the operating equipment / parameters is not impossible.
  47. 47. Seamlessness
  48. 48. understanding the existing process capabilities and scope of stretching the process.
  49. 49. Developed high level of confidence to accomplish the project within stipulated time and allocated budget with the judicious use of existing resources & sweating of assets.
  50. 50. Enhanced team spirit, Synergy through cohesive working.
  51. 51. Identification of individual potential working in a group that can be useful in years to come.</li></li></ul><li>Thank you<br />
  52. 52. VAM UNIT<br />
  53. 53. Centrifugal Machine<br />Old Centrifugal M/C<br />
  54. 54. Vanadium Plant<br />
  55. 55. Refrigeration Unit<br />
  56. 56. Decanter Machine<br />DECANTER M/C<br />
  57. 57. Achievement Core Team<br />EQUIPMENT ON/OFF INDICATION & TEMP. SCANNER / RECORDER<br />42<br />
  58. 58. Achievement Core Team<br />INCREASED NO. OF PLATES IN OLD PHE<br />NEW PHE INSTALLED<br />43<br />
  59. 59. FLOW ELEMENT<br />Achievement Core Team<br />44<br />
  60. 60. AMMONIA COMPRESSOR<br />Achievement Core Team<br />45<br />
  61. 61. Schematic Diagram Vanadium Plant (After)<br />PHE<br />
  62. 62. Brief Background<br />Successive Increase of Vanadium impurity<br />
  63. 63. Brief Background<br />
  64. 64. Brief Background<br />