Purpose
Key to good performance
Problem Areas
Catalysts, heat shields and plant up-rates
Burner Guns
Development of High Intensity Ring Burner
Case Studies
Conclusions
Purpose
Key to good performance
Problem Areas
Catalysts, heat shields and plant up-rates
Burner Guns
Development of High Intensity Ring Burner
Case Studies
Conclusions
AccuThermo AW 610 Rapid Thermal Annealing EquipmentPeter Chen
The AccuThermo AW610 was derived from the AG Associates 610 production-proven design. Allwin21 Corp. is the exclusive manufacturer of the AG Associates Heatpulse 610 desktop atmospheric RTP (Rapid Thermal Processing) system. The system uses high intensity visible radiation to heat single wafer for short process periods of time at precisely controlled temperatures. The process periods are typically 1 600 seconds in duration, although periods of up to 9999 seconds can be selected. These capabilities, combined with the heating chamber's cold-wall design and superior heating uniformity, provide significant advantages over conventional furnace processing.
Optimizing Combustion - Transcending the "Flat Earth Era"Yokogawa1
Has combustion automation changed much since the advent of the distributed control system (DCS)? When automobile technology transitioned from carburetors to fuel injection, it brought a new standard of safe, reliable, clean, efficient performance. However, other than widespread adoption of NFPA codes, operation of fired assets such as heaters, furnaces, ethane crackers, and steam methane reformers really hasn’t changed much in decades. Imprecise, inaccurate, and often corrupted process data conspires to leave operators with sloppy control loops and ambiguities, which lead to questions such as:
• Do I really know that my purge is complete?
• What are my ideal set points?
• Can I truly trust the data on my screen?
• How close to ideal can I safely run?
• How do I know when I’m operating dangerously?
• When I get in trouble, is a trip my only recourse?
These uncertainties can produce inconsistent decisions and, in turn, unnecessary fuel consumption, non-optimal process throughput, excessive emissions, accelerated aging of assets, increased maintenance, and, most importantly, safety compromises.
It doesn’t have to be like this; there’s a better way to combust. With its initial founding derived from the recommendations of IEC 556, Yokogawa has re-drawn the limits of safe, efficient, clean combustion. Through the proven path of CombustionONE, Yokogawa welcomes all fired asset operators to explore beyond the "Flat Earth Era" of combustion automation.
We have been recently Certified by Engineers India Limited ( EIL) for the Shell & Tube Waste Heat Recovery Boilers WHRB are fire tube industrial boilers equipped with advanced instrumentation to deliver maximum possible heat recovery.
Australasian Lab managers Conference: Gas Generation Dr Nicole Pendini 2019Nicole Renee Pendini
This presentation focus on on-site Gas Generation for the laboratory space supplying a range of analytical and specialty applications within the lab environment. I will focus on keeping green by preventing weekly cylinder and bulk supply deliveries, that waste energy offsite to generate the gas and petrol to delivery to the laboratory. The overall cost savings vs other methods (ROI < 1.5 years including service) and of course how Laboratory managers can significantly reduce their OHS/E risk with onsite Nitrogen, Hydrogen and Zero Air gas generators.
A report on Economic Feasibility for a chemical Process.(For details on Appen...Parag Patil
A Report prepared for a chemical process based on its economic feasibility and safety.
Its totally an academic project!
The course was named as "Process Analysis and Simulation" at IIT Gandhinagar,.
Objective of the study is as follows: To know how to optimize the process parameters to increase the production quality given set of possible constrains for a process.
I used the ASPEN Package to do the same and some basic calculations based on a book!
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
Forklift Classes Overview by Intella PartsIntella Parts
Discover the different forklift classes and their specific applications. Learn how to choose the right forklift for your needs to ensure safety, efficiency, and compliance in your operations.
For more technical information, visit our website https://intellaparts.com
AccuThermo AW 610 Rapid Thermal Annealing EquipmentPeter Chen
The AccuThermo AW610 was derived from the AG Associates 610 production-proven design. Allwin21 Corp. is the exclusive manufacturer of the AG Associates Heatpulse 610 desktop atmospheric RTP (Rapid Thermal Processing) system. The system uses high intensity visible radiation to heat single wafer for short process periods of time at precisely controlled temperatures. The process periods are typically 1 600 seconds in duration, although periods of up to 9999 seconds can be selected. These capabilities, combined with the heating chamber's cold-wall design and superior heating uniformity, provide significant advantages over conventional furnace processing.
Optimizing Combustion - Transcending the "Flat Earth Era"Yokogawa1
Has combustion automation changed much since the advent of the distributed control system (DCS)? When automobile technology transitioned from carburetors to fuel injection, it brought a new standard of safe, reliable, clean, efficient performance. However, other than widespread adoption of NFPA codes, operation of fired assets such as heaters, furnaces, ethane crackers, and steam methane reformers really hasn’t changed much in decades. Imprecise, inaccurate, and often corrupted process data conspires to leave operators with sloppy control loops and ambiguities, which lead to questions such as:
• Do I really know that my purge is complete?
• What are my ideal set points?
• Can I truly trust the data on my screen?
• How close to ideal can I safely run?
• How do I know when I’m operating dangerously?
• When I get in trouble, is a trip my only recourse?
These uncertainties can produce inconsistent decisions and, in turn, unnecessary fuel consumption, non-optimal process throughput, excessive emissions, accelerated aging of assets, increased maintenance, and, most importantly, safety compromises.
It doesn’t have to be like this; there’s a better way to combust. With its initial founding derived from the recommendations of IEC 556, Yokogawa has re-drawn the limits of safe, efficient, clean combustion. Through the proven path of CombustionONE, Yokogawa welcomes all fired asset operators to explore beyond the "Flat Earth Era" of combustion automation.
We have been recently Certified by Engineers India Limited ( EIL) for the Shell & Tube Waste Heat Recovery Boilers WHRB are fire tube industrial boilers equipped with advanced instrumentation to deliver maximum possible heat recovery.
Australasian Lab managers Conference: Gas Generation Dr Nicole Pendini 2019Nicole Renee Pendini
This presentation focus on on-site Gas Generation for the laboratory space supplying a range of analytical and specialty applications within the lab environment. I will focus on keeping green by preventing weekly cylinder and bulk supply deliveries, that waste energy offsite to generate the gas and petrol to delivery to the laboratory. The overall cost savings vs other methods (ROI < 1.5 years including service) and of course how Laboratory managers can significantly reduce their OHS/E risk with onsite Nitrogen, Hydrogen and Zero Air gas generators.
A report on Economic Feasibility for a chemical Process.(For details on Appen...Parag Patil
A Report prepared for a chemical process based on its economic feasibility and safety.
Its totally an academic project!
The course was named as "Process Analysis and Simulation" at IIT Gandhinagar,.
Objective of the study is as follows: To know how to optimize the process parameters to increase the production quality given set of possible constrains for a process.
I used the ASPEN Package to do the same and some basic calculations based on a book!
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
Forklift Classes Overview by Intella PartsIntella Parts
Discover the different forklift classes and their specific applications. Learn how to choose the right forklift for your needs to ensure safety, efficiency, and compliance in your operations.
For more technical information, visit our website https://intellaparts.com
Hierarchical Digital Twin of a Naval Power SystemKerry Sado
A hierarchical digital twin of a Naval DC power system has been developed and experimentally verified. Similar to other state-of-the-art digital twins, this technology creates a digital replica of the physical system executed in real-time or faster, which can modify hardware controls. However, its advantage stems from distributing computational efforts by utilizing a hierarchical structure composed of lower-level digital twin blocks and a higher-level system digital twin. Each digital twin block is associated with a physical subsystem of the hardware and communicates with a singular system digital twin, which creates a system-level response. By extracting information from each level of the hierarchy, power system controls of the hardware were reconfigured autonomously. This hierarchical digital twin development offers several advantages over other digital twins, particularly in the field of naval power systems. The hierarchical structure allows for greater computational efficiency and scalability while the ability to autonomously reconfigure hardware controls offers increased flexibility and responsiveness. The hierarchical decomposition and models utilized were well aligned with the physical twin, as indicated by the maximum deviations between the developed digital twin hierarchy and the hardware.
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
NUMERICAL SIMULATIONS OF HEAT AND MASS TRANSFER IN CONDENSING HEAT EXCHANGERS...ssuser7dcef0
Power plants release a large amount of water vapor into the
atmosphere through the stack. The flue gas can be a potential
source for obtaining much needed cooling water for a power
plant. If a power plant could recover and reuse a portion of this
moisture, it could reduce its total cooling water intake
requirement. One of the most practical way to recover water
from flue gas is to use a condensing heat exchanger. The power
plant could also recover latent heat due to condensation as well
as sensible heat due to lowering the flue gas exit temperature.
Additionally, harmful acids released from the stack can be
reduced in a condensing heat exchanger by acid condensation. reduced in a condensing heat exchanger by acid condensation.
Condensation of vapors in flue gas is a complicated
phenomenon since heat and mass transfer of water vapor and
various acids simultaneously occur in the presence of noncondensable
gases such as nitrogen and oxygen. Design of a
condenser depends on the knowledge and understanding of the
heat and mass transfer processes. A computer program for
numerical simulations of water (H2O) and sulfuric acid (H2SO4)
condensation in a flue gas condensing heat exchanger was
developed using MATLAB. Governing equations based on
mass and energy balances for the system were derived to
predict variables such as flue gas exit temperature, cooling
water outlet temperature, mole fraction and condensation rates
of water and sulfuric acid vapors. The equations were solved
using an iterative solution technique with calculations of heat
and mass transfer coefficients and physical properties.
NO1 Uk best vashikaran specialist in delhi vashikaran baba near me online vas...Amil Baba Dawood bangali
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HEAP SORT ILLUSTRATED WITH HEAPIFY, BUILD HEAP FOR DYNAMIC ARRAYS.
Heap sort is a comparison-based sorting technique based on Binary Heap data structure. It is similar to the selection sort where we first find the minimum element and place the minimum element at the beginning. Repeat the same process for the remaining elements.
Immunizing Image Classifiers Against Localized Adversary Attacksgerogepatton
This paper addresses the vulnerability of deep learning models, particularly convolutional neural networks
(CNN)s, to adversarial attacks and presents a proactive training technique designed to counter them. We
introduce a novel volumization algorithm, which transforms 2D images into 3D volumetric representations.
When combined with 3D convolution and deep curriculum learning optimization (CLO), itsignificantly improves
the immunity of models against localized universal attacks by up to 40%. We evaluate our proposed approach
using contemporary CNN architectures and the modified Canadian Institute for Advanced Research (CIFAR-10
and CIFAR-100) and ImageNet Large Scale Visual Recognition Challenge (ILSVRC12) datasets, showcasing
accuracy improvements over previous techniques. The results indicate that the combination of the volumetric
input and curriculum learning holds significant promise for mitigating adversarial attacks without necessitating
adversary training.
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
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
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
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
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
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
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
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
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
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
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
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)
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
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
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
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.
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.