team hindalco welcomes you all - knowledge platform...hindalco, the flagship company of the aditya...
TRANSCRIPT
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Team Hindalco
Welcomes You All
Hindalco Industries Limited, Renukoot
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Team Introduction
2
Vibhav Upadhyay
Anuj Verma
Vivek Agrawal
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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,
Renukoot
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To Reduce Pot Voltage at Renukut
Smelter to Enhance Energy Efficiency
16 Nov 2016 4
Project Theme
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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,
Renukoot
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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 Renukoot: Profile
Hindalco Industries Limited,
Renukoot
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Finish Product
Aluminium
Hindalco Renukoot : Fully Integrated Operations
Alumina Bauxite
Captive Power
TH
RO
UG
H
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Typical Cost of Aluminium Production
Smelter Power 40%
Store, potlini ng, misc.
4%
AlF3 1%
Depriciation 1%
Net carbon 15%
Alumina 35%
wages 5%
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Renukut Smelter
•Renukut smelter has 11 pot lines and 2138 Electrolytic cells
(pots). Annual Aluminum Production is 409 KT.
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Process Description ALUMINA HOPPER
ANODE (+)
ANODE (+)
MOLTEN CRYOLITE BATH MOLTEN ALUMINIUM
CATHODE BLOCK (-)
POINT FEEDERS
SiC BRICKS
DIATHERM 23
INSULATION
BRICKS
CATHODE BUS BAR
COLLECTOR
BAR
POT COVERS
ALUMINA
INSULATION
FROZEN BATH
CRUST
TOE PLATE
MONOLITHIC PASTE
LINING
DENSE FIRE
BRICKS
2 AI2O3 + 3 C 4 AI + 3 CO2
ANODE RING BUS
CALCIUM
SILICATE
INSULATION
MOLTEN METAL
According to Faraday’s Law:
Production = 8.052* Amperage*Current Efficiency 10
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Project background
•Power Consumption
298/ CE
VkgkWh
4.420
4.440
4.460
4.480
4.500
4.520
4.540 Pot voltage, V
This project was taken to reduce pot voltage by 80 mv
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Problem Diagnosis
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Project Scoping
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Approach
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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
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Macro Map
Pot Lining
-New pot shell
-Refractory lining
Pot baking
-Pot taken
in circuit
Pot Loading
-Pot taken in
operation
Alumina Feeding
-Installation of point
feeders and Micro
Processor control
Metal Tapping
-Metal tap out in
cruce
Crust breaking
-Crust breaking
- Bath melting
Bath maintenance
- Solid bath addition
Anode changing
-Spent anode removal
Dust skimming
-New anode set
- Anode covering
Sampling
-Bath ratio, temperature
- Bath Level
measurement
•DC Power from Rectifier
•Anodes from carbon
plant
-Corrections
-Bath ratio balance
by adding AlF3 or
Soda ash
- Bath maintenance
•Primary alumina from Alumina
plant
•Secondary alumina through DSS
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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
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ACD
Cathode Voltage drop
Pot age
Noise
Alumina concentration
Metal level
Anode effect
Bath Chemistry
Clamp drop
Diamond drop
Critical parameters
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Regression Analysis
Correlation & regression analysis carried out to find out
most critical parameters 18
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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.
.
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Pot age ,ACD ,Noise ,CVD, Bath Chemistry
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Problem Remedy
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Voltage Reduction Plan
Problem Remedy
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.
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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
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ACD
1. No voltage reduction if pot is under high noise, low bath level,
metal left in the pot, and less current anodes
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Control Plan
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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.
Control plan for Improvement
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• 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
Replication
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Results
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Tangible Results
July'15 Aug'15 Sep'15 Oct'15 Nov'15 Dec'15 Jan'201
6 Feb'16 Mar'16
Pot voltage 4.515 4.513 4.479 4.470 4.453 4.448 4.450 4.444 4.442
Volts/p
ot
Pot voltage
Strict follow up of action plan led to reduction in pot voltage 27
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Tangible Results
4.400
4.420
4.440
4.460
4.480
4.500
4.520
4.540
July
'15
Aug'1
5
Sep'1
5
Oct'1
5
Nov'1
5
Dec'1
5
Jan
'20
16
Feb'1
6
Mar'16
Volts/p
ot
Pot voltage
• Improvement in CTQ
28
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Tangible Results
13800
13850
13900
13950
14000
14050
14100
14150
14200
14250
14300
Ju
ly'1
5
Au
g'1
5
Se
p'1
5
Oct'15
No
v'1
5
De
c'1
5
Ja
n'2
01
6
Fe
b'1
6
Ma
r'1
6
Power, kWh/T
•Improvement in Power consumption
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Tangible Results
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Power consumption reduced by
284 kWh/ T
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• Enhance in process consistency also improved
metal purity
• Lowest Iron content and Silicon content in
aluminium.
• Increased Internal customer satisfaction
Intangible Results
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Thank You
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