Automatic draft adjustment in FTC by use of impulse type pressure transmitter , replacing capillary type ones

1. PRAGATI
JOURNEYNEVERENDS

2. Team Introduction
TEAM PRAGATI
• Alok
Samanta
• ABF Operations
• Satyapriya
Pradhan
• Sourish
Thakur
• Prabhat Kumar
Acharya
• Mechanical
2
• ABF
Operations
• ABF
Operations

3.  COMPANY : ADITYA ALUMINIUM
 DEPARTMENT : CARBON PLANT/ABF
 QC NUMBER : HIL/AAP/QC/T27
 NO. OF MEMBERS : 5Nos
 DATE OF FORMATION : 12/01/2019
 MEETINGS DAY : EVERY SATURDAY
 MEETINGS VENUE : LCR3(ABF Control Room)
 MEETINGS TIME : 10:00 – 11:00 AM
 NO. OF MEETINGS : 182
 ATTENDANCE : 91 %
BRIEF HISTORY OF OUR QUALITY CIRCLE

4. OUR ACHIEVEMENTS
Our team won Silver award in CCQC-2019

5. OUR ACHIEVEMENTS

6. VALUES
Vision
To deliver superior value
to our internal & external
customers and other
stake holders Mission
To be a premium primary
aluminium producer with
clear focus on Profit,
People & Planet
We manufacture
materials that make the
world greener, stronger
& smarter
Purpose
ADITYA ALUMINIUM

7. ALUMINIUM SMELTER OVERVIEW
RODDING SHOP
GREEN
ANODE
BAKED
ANODE
CAPTIVE
POWER PLANT
ALUMINA HANDLING
STATION
POWER
ALUMINA
RODDED
ANODE
POT LINE CASTHOUSE
INGOT
ANODE BAKING
FURNACE
GREENANODE
PLANT
MOLTEN
METAL
POWER
PLANT
CARBON
PLANT
ALUMINA
HANDALING
POT ROOM CAST HOUSE

8. Green
Anode
from GAP
Green Anode
Handling &
Storage
Green Anode
Packing in Furnace
Fire
Operation/Baking
Baked Anode
Unpacking
Baked Anode Cleaning
& Storage
FTC Operation
Baked
Anode to
Rodding
HFO Storage &
Handling
ANODE BAKING-KEY PROCESS
ADITYA ANODE PRODUCTION CAPACITY-672nos/day
(28 Hour fire cycle in Aditya furnace)
HIRAKUD ANODE PRODUCTION CAPACITY-336nos/day
(24 Hour fire cycle in Hirakud furnace)
ADITYA Baked Anode

9. OVERVIEW OF DMAIC METHOD

10. Define what is the problem, understand the problem and
the process generating it. Define project objective and goal.
M for Measure – Measure the magnitude of the
problem and identify/collect the data required.
Identify the vital few root causes of the
defects.
Identify and select the most optimal solution for the
significant root causes.
Monitor and control the process
performance to ensure sustainable
results.
WHAT IS D-M-A-I-C !?!
c
I
A
M
D

11. TOOL USED
 BRAINSTORMING 4 POINT RATING SCALE
2. SELECTION OF THE PROBLEM

12. SELECTION OF THE PROBLEM
Sr. No. Problem Description
Rating (1 to 4)
(4 for high priority,1 for least priority)
Safety(A) Quality(B) Cost(C) Environment(D)
Rating
(A*B*C*D)
1 Non uniformity of top coke layering in abf1&2 4 4 2 1 32
2
FTC2 bag house recirculation box mesh
damage.
4 4 2 3 96
3 FTA Suction rate is not in standard(80m3/hr.) 3 3 2 4 72
4 Ftc1&2 inlet plenum jamming. 4 4 2 2 64
5 Exhaust ramp draft deviation is high in furnace 4 4 3 3 144

13. 2. SELECTION OF THE PROBLEM

14. SELECTION OF THE PROBLEM
Exhaust ramp draft deviation is high in
furnace ?
We select our problem

15. TARGET PLAN
END DATE TOTAL DAYS
PLAN
ACTUAL w3 w4 w1 w2 w3 w4 w1 w2 w3 w4 w1 w2 w3 w4
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
6 control Sourish
Prepared By:Satyapriya
4 Analyse the Problem Alok
5 Improve Pravat
2 Define the Problem Satyapriya
3 Measure the Problem Sourish
Mar-22 Apr-22
1 Selection of Problem Alok
Sl.No STEP DESCRIPTION RESPONSIBILITY
Jan-22 Feb-22
PLANT:ADITYA ALUMINIUM DEPARTAMENT: ABF TEAM: PRAGATI
START DATE
WORKING WEEKS
18-01-2022
PLAN ACTUAL

16. DEFINE PHASE
TOOL USED
 PROCESS FLOW DIAGRAM

17. IMPACT OF THE PROBLEM
Productivity
Quality
Cost
1. Due to a low draft, the fire change got delayed.
2. A low draft in the furnace frequently causes the HR
nozzle to jam.
1. Improper pitch burning.
2. Draft loss during fire movement causes HR to stop and temperature lag.
3. Low draft causes a loss of temperature in the ER.
4. Frequent fire stoppages.
1. High power consumption due to variations in furnace draft.
2. Extra manpower engaged for ER and furnace duct cleaning.
3. Increased HFO consumption.

18. OBJECTIVE AND GOALS
 We will run the FTC id fan in such a way so that all 4 fire will maintain the draft i.e. -1500pa
 ON time fire change.
GOAL
 We run the FTC operation having no manual intervention
OBJECTIVE

19.  There are two numbers of Anode baking furnace(ABF) at
Aditya Aluminium .The ABF-1 which caters the anode
requirement of Aditya smelter has a production capacity
of 672 anodes/day whereas ABF-2 caters the anode
requirement of Hirakud Smelter with a production
capacity of 336 anodes/day.
 After production of green anode from Green Anode Plant
(GAP), the anodes need to be baked in ABF at a
temperature of 1100 deg C in order to improve electrical
conductivity, enhance thermal & chemical stability.
 EXHAUST ramp is present in the fire to exhaust the
fume during anode baking process through connected
duct. Then after fume getting suction from duct by fume
centre id fan.
DEFINE OF THE PROBLEM

20. U
N
P
A
C
K
I
N
G
S
E
C
T
I
O
N
S
E
A
L
I
N
G
S
E
C
T
I
O
N
P
A
C
K
I
N
G
S
E
C
T
I
O
N
R
E
F
R
A
C
T
O
R
Y
M
A
N
T
S
E
C
FIRE Configuration
HEATING ZONE
PRE
HEATING ZONE
BLOWING
ZONE
FORCED
COOLING ZONE
 Total 15 section in 1 Fire includingAnode packing and Anode Packing Section
 1 fire consists of:
 1 Exahust Ramp
 1Temperature Pressure Ramp
 3 Heating Ramp
 1 Blowing Ramp
 1 Zero Pressure Ramp
 2 Cooling Ramp
Air Blow Gas to FTC
HFO Pulsing
HotAir
Fire Direction
Cooling Ramp
Blowing
Ramp Heating Ramps

21. H
E
A
D
W
A
L
L
TOP BLOCK
H
E
A
D
W
A
L
L
TOP BLOCK TOP BLOCK TOP BLOCK
B
A
F
F
L
E
S
B
A
F
F
L
E
S
B
A
F
F
L
E
S
TOP BLOCK TOP BLOCK
1 SECTION
Hot Gas Movement inside Flue walls
F L U E W A L L

22. COOLING
TOWER
AIR
LIFT
ID FANS
WATER
AIR
FEEDER
ENRICHE
D
ALUMINA
RECIRCUL
-ATION
OPEN
CLEAN GAS
COMPRESSED AIR
SPRAY BOOSTER
PUMP
Anode
Baking
Furnace ToGTC
Vibrating Screen
RAL
GENERAL
BYPASS
DAMPER
CLOSE
ISOLATIO
N DAMPER
OPEN
TREATMEN
T BYPASS
DAMPER
CLOSED
S
T
A
C
K
130-240°C
125-200°C
Gas Temperature Less
than 110°C
Flue Gas Treatment Mode (Central Mode)
V
R
I
BAG
HOUSE
BAG
HOUSE
OUTLET
DAMPER
OPEN
Treatment Mode
Treatment Bypass Mode
General Bypass Mode
Fresh
Alumina
Silo
Enriched
Alumina
Silo
DP 1.45
Gas Temperature
More Than 110°C
Vibratin
g Screen
Furnace outlet
pressure
transmitter

23. MEASURE PHASE

24. How it has
occurred ?
Furnace
outlet
pressure
varies
What was the problem?
Exhaust
ramp draft
deviation is
high in
furnace
Where it has
occurred ?
ABF-1
furnace
When it was
occurring ?
During ID
fan running
Who Is Involved?
Control room
in charge and
Fire operator
4 W 1 H

25. Data Analysis
We analyse the FTC Id fan speed data that average Id fan speed value i.e 84%

26. Data Analysis
0
10
20
30
40
50
60
70
80
90
PERCENTAGE
DAYS
FTC ID FAN SPEED

27. ANALYZE PHASE

28. IDENTIFICATION OF CAUSES
Fish Bone Diagram
Exhaust ramp
draft
deviation is
high in
furnace
MACHINE
ENVIRONMENT
MEASUREMEN
T
METHOD
Manual speed
increase
ID fan running
Procedure not
known
FTC SCADA not
operated by
control room in
charge
Furnace outlet Pressure
Transmitter value not
correct.
PressureTransmitter not
working
Pressure increase in
day time
Pressure increase in
Night time
Pressure decrease in
day time
Pressure decrease in
day time
long time fire
change
ER not working
ER Individual damper
open is high
Sealing damper
cloth damage
Id fan not
running in
auto mode
ER flue wall
damper not
working
TPR pressure not
showing correct
value
ID fan not working
properly
High
vibration
ID fan impeller
leakage
Leakages in
furnace
No Polythene cover in
sealing section
ER not
cleaning
Leakage in fume duct

29. FINDING ROOT CAUSES

30. FIND THE ROOT CAUSES
leakages in
ER flexible.
Check found
no leakage
TPR pressure not
showing correct
value
Transmitte
r is fixed as
per design
ER not cleaning
Damper
opening as
per set draft
Leakage in fume
duct
having
deviation
during
checking
Furnace outlet
Pressure
Transmitter value
not correct.
Checked
found ok
FTC ID fan speed
increases
manually.
ER duct
cleaning in
monthly
basis
pressure
transmitter
not in proper
location?
Manual
speed
increases
with constant
value.
Sealing damper
cloth damage
.
Fire change
under 30mins
ER Individual
damper
open is high
Duct checked
found no
leakage
Long time fire
change
Checked
found ok

31. 1
Furnace outlet PressureTransmitter value not correct.
2
FTC ID fan speed increases manually.
Root Cause Analysis
Yes, We Found
the Root Cause

32. Data Analysis

33. Data Analysis
We found that the Furnace outlet PressureTransmitter value was
incorrect, leading to the manual increase in ID fan speed. From these
two issues,We collected the furnace outlet transmitter pressure data
as it is varies by manual increase in ID fan speed.

34. Data Collection
We got our root causes that both pressure transmitter
value and manual speed increase causes furnace outlet
draft deviation is high the automatically ER draft
deviation is high in furnace.
We collected the furnace outlet transmitter pressure
date it shown that,
RESULTS
0
0.5
1
1.5
2
2.5
3
12/1/2021
12/3/2021
12/5/2021
12/7/2021
12/9/2021
12/11/2021
12/13/2021
12/15/2021
12/17/2021
12/19/2021
12/21/2021
12/23/2021
12/25/2021
12/27/2021
12/29/2021
12/31/2021
AVERAGE FURNACE OUTLET
PRESSURE(KPA)

35. (Data analyzed from FTC SCADA)
DATA COLLECTION

36. IMPROVE PHASE

37. DEVELOPING SOLUTION
SL NO ROOT CAUSE SOLUTION PROPOSED ACCEPT/REJECT REASON OF REJECT/ACCEPT
1
Furnace outlet
Pressure
Transmitter
value not
correct.
Replaced with new one Reject same value will show
Change it to impulse type
transmitter
Accept
accurately from the pipe tapping
point to the transmitter
Change the location Reject Value difference will not change

38. DEVELOPING SOLUTION
SL NO ROOT CAUSE SOLUTION PROPOSED ACCEPT/REJECT REASON OF REJECT/ACCEPT
2
FTC ID fan
speed
increases
manually
keep it same reject Pressure deviation will be high
Will run the Id fan in auto mode Accept
Speed will increase/decrease as
per the set pressure
ID Fan will run with Furnace outlet
pressure
Accept
ID fan will run as per furnace out
let pressure

39. Capillary type to Impulse
type transmitter ID Fan run in auto mode
ID Fan will run with
Furnace outlet pressure
BRAINSTORMING
IMPROVEMENT SOLUTION

40. MANAGEMENT OF CHANGE

41.  To Improve Anode quality & performance in pot
room by increasing Cleaning efficiency.
 100% Slot cleaning not possible by both anode
cleaning machine due to design issue.
 Recovery of packing coke was not possible due
to improper cleaning and it is affecting the
specific packing coke consumption.
 Loose packing coke in anode slot creating
Dusting problem in Pots and affecting pot
parameters & current efficiency negatively.
IMPLEMENTATION

42. ACTION PLAN
Sl.no ACTION PLAN Responsibility Target Date
1 Procurement of impulse transmitter Alok Samanta 07-03-2022
2 Installation of impulse transmitter Pravat /Satya
25-03-2022
3 Automation with existing system
Alok Samanta
/Sourish
30-03-2022

43. IMPROVEMENT

44. CONTROL PHASE

45. REGULAR IMPLEMENTATION
SOPTRAINING
After Successful implementation we observed that id fan is running with average speed of 77% with draft at Furnace is
1500pa +/- 50 pa

46. REGULAR IMPLEMENTATION
After Successful implementation we observed that id fan is running with average speed of 77% with draft at Furnace is
1500pa +/- 50 pa
ID FAN SPEED IN PERCENTAGE
Furnace out let pressure

47. DATE SHIFT: FTC 1MODE OPERATOR FTC2MODE
SL NO FTC1 OBSERVATIONS OK/NO ACTION TAKEN FTC2 OBSERVATIONS OK/NO
1 CT SPRAY LANCE 1 TO 5 CT SPRAY LANCE 1 TO 5
AIR/WATER PRESSURE AIR/WATER PRESSURE
SPRAY BOOSTER PUMP SPRAY BOOSTER PUMP
Furnace outlet Pressure Transmitter Furnace outlet Pressure Transmitter
out let pressure PU Tube out let pressure PU Tube
SPRAY TANK LEVEL SPRAY TANK LEVEL
VALVE RACK IN OPERATION VALVE RACK IN OPERATION
AIR PRESSURE AIR PRESSURE
WATER PRESSURE WATER PRESSURE
2 DP BAG HOUSE 1 TO 5 DP BAG HOUSE 1 TO 5
BH AIR PULSING BH AIR PULSING
BH PULSE AIR PRESSURE BH PULSE AIR PRESSURE
BH RECIRCULATION ON & FINE BH RECIRCULATION ON & FINE
3 FA FEEDING TO BH 1 TO 5 FA FEEDING TO BH 1 TO 5
RA CONVEYING BH TO AIRLIFT RA CONVEYING BH TO AIRLIFT
RA CONVEYING AIRLIFT TO V/S RA CONVEYING AIRLIFT TO V/S
FA/RA VIBRATING SCREEN FA/RA VIBRATING SCREEN
RA CONVEYING TO AHS RA CONVEYING TO AHS
4 RA AIRLIFTER BLOWER OK/FINE RA AIRLIFTER BLOWER OK/FINE
HOPPER FLUIDISING BLOWER HOPPER FLUIDISING BLOWER
FUME TREATMENT CENTRE CHECKLIST
STANDARDIZATION
There is a change in the FTC 1&2
checklist due to new updates.
DATE SHIFT: FTC 1MODE OPERATOR FTC2MODE
SL NO FTC1 OBSERVATIONS OK/NO ACTION TAKEN FTC2 OBSERVATIONS OK/NO
1 CT SPRAY LANCE 1 TO 5 CT SPRAY LANCE 1 TO 5
AIR/WATER PRESSURE AIR/WATER PRESSURE
SPRAY BOOSTER PUMP SPRAY BOOSTER PUMP
Furnace outlet Pressure Transmitter Furnace outlet Pressure Transmitter
out let pressure PU Tube out let pressure PU Tube
SPRAY TANK LEVEL SPRAY TANK LEVEL
VALVE RACK IN OPERATION VALVE RACK IN OPERATION
AIR PRESSURE AIR PRESSURE
WATER PRESSURE WATER PRESSURE
2 DP BAG HOUSE 1 TO 5 DP BAG HOUSE 1 TO 5
BH AIR PULSING BH AIR PULSING
BH PULSE AIR PRESSURE BH PULSE AIR PRESSURE
BH RECIRCULATION ON & FINE BH RECIRCULATION ON & FINE
3 FA FEEDING TO BH 1 TO 5 FA FEEDING TO BH 1 TO 5
RA CONVEYING BH TO AIRLIFT RA CONVEYING BH TO AIRLIFT
RA CONVEYING AIRLIFT TO V/S RA CONVEYING AIRLIFT TO V/S
FA/RA VIBRATING SCREEN FA/RA VIBRATING SCREEN
RA CONVEYING TO AHS RA CONVEYING TO AHS
4 RA AIRLIFTER BLOWER OK/FINE RA AIRLIFTER BLOWER OK/FINE
HOPPER FLUIDISING BLOWER HOPPER FLUIDISING BLOWER
FUME TREATMENT CENTRE CHECKLIST

48. STANDARDIZATION
There has been a change in the FTC
Operation SOP.

49. FOLLOW UP / REVIEW
Training given to Operator about FTC
operation

50. CONCLUSION
Before
 Improper pitch burning.
 Draft loss during fire movement causes HR stopped and temperature lagging.
 Frequent fire stoppage.
 Due to low draft Fire change got delayed.
 Furnace low draft causes frequently hr nozzle jammed.
 High power consumption due to variation of furnace draft.
After
All issues solved

51. TARGET V/S ACTUAL
END DATE TOTAL DAYS
30-04-2022 103
PLAN
ACTUAL w3 w4 w1 w2 w3 w4 w1 w2 w3 w4 w1 w2 w3 w4
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLANT:ADITYA ALUMINIUM DEPARTAMENT: ABF TEAM: PRAGATI
START DATE
WORKING WEEKS
18-01-2022
1 Selection of Problem Alok
2 Define the Problem Satyapriya
Sl.No STEP DESCRIPTION RESPONSIBILITY
Jan-22 Feb-22 Mar-22 Apr-22
3 Measure the Problem Sourish
4 Analyse the Problem Alok
Prepared By:Sourish Thakur
5 Improve Pravat
6 control Sourish
PLAN ACTUAL

52. TANGIBLE BENEFIT
condition Id fan
speed
Running
hrs/month
Energy consumption/month saving/month
Before 84% 1440
1440*0.84*300=362880 kwh
30240 kwh
After 77% 1440
140*0.77*300=332640 kwh
1 unit cost=6.95 Rupees
Monthly saving=6.95*30240kwh=2.1lakhs
For 2 id fans=2.1*2=4.2 lakhs/annum
Yearly saving=4.2*12=50.4 lac Rupees
FOR 1 ID FAN

53. TANGIBLE BENEFIT
ByTargeting our Group Sustainability
Zero Carbon Emissions by 2050
60480 kw power saved, Which will electrify
300 household for one month.
We saved Approximately 2.8 tons
of Coal per Month.
SUSTAINABILITY

54. INTANGIBLE BENEFIT
Elimination of Un-necessary manual intervention.
Self & mutual development of team members
Gained knowledge of problem solving tools & technique
Improved problem solving ability
Increased Team Co-ordination
Source of inspiration for other colleagues.

55. TOOLS & TECHNIQUES USED
 BRAIN STORMING
 RANKING METHOD
 MILESTONE CHART
 FLOW CHART
 DATA COLLECTION
 4W-1H ANALYSIS
 FISH-BONE DIAGRAM
 PDCA CYCLE

56. ACKNOWLEDGEMENTS
OUR NEXT PROJECT
Vibrating screen bellow getting damaged?
We are very grateful to Carbon HOD Mr Amit
Bhardwaj who continuously supported us and
encouraged us to achieve this.
Also we are proud of our team where everyone
actively participated by giving their inputs as well
as to all others who through whatsoever inputs
made this project a success.

57. Any Querries