SECOND WORKSHOP ON PROMOTING EXCHANGE OF BEST PRACTICES IN ENERGY EFFICIENCY IN ALUMINIUM SECTOR UNDER KEP INITIATIVE
Date(s) - 16/12/2016 - 17/12/2016
9:00 am - 6:00 pm
Hindalco Industries Limited
16th -17th December, 2016, Hirakud, Odisha: The 2nd Workshop on ‘Promoting Exchange of Best Practices in the area of Energy Efficiency in Aluminium Sector’ was organized on 16th– 17th December 2016, Hirakud, Odisha. The workshop was hosted by Hindalco Industries Limited and organized under the Knowledge Exchange Platform (KEP) initiative. KEP is a joint initiative of Bureau of Energy Efficiency (BEE) and Institute for Industrial Productivity (IIP) to promote energy efficiency by facilitating exchange of knowledge, experiences and best practices in industries covered under the Perform Achieve and Trade (PAT) scheme.
The workshop was inaugurated by Shri R K Gupta, Sr. President & Head-Sambalpur Cluster, Hindalco Industries Limited. In his inaugural address, he congratulated the numerous initiatives that KEP has undertaken in a very short span of time to facilitate exchange of knowledge and best practices through these workshops. He also appreciated KEP for initiating interactions between Aluminium & Cement industries to discuss the existing issues and challenges being faced by them in promoting use of spent pot liner (SPL), which is a hazardous waste produced in aluminium industry. He informed the participants that Ultratech Cement Limited is going for SPL trial and hoped that some positive results will come out which will help both the industries to further strategize the ways to address the existing barriers.
Welcome address and introduction to the workshop was delivered by Shri K K Chakarvarti, Expert Consultant, Bureau of Energy Efficiency. He provided an update on KEP initiatives and mentioned that in order to ensure that KEP continues to act as a forum for sustain interaction within and across industry sectors, it is important that KEP’s efforts are strengthened by providing continuous input and feedback. He informed that besides initiating sectoral workshop, quarterly newsletter, best practice exchange visits, KEP has also developed an interactive website. Shri Chakarvarti concluded his welcome address by stating that focus of KEP in its second year of operation is to assess the technology gap and promote energy efficient technologies in the PAT Sectors.
Dr. Anupam Agnihotri, Director, Jawaharlal Nehru Aluminium Research Development and Design Centre (JNARDDC), in his special address congratulated the Aluminium sector for their outstanding performance in PAT Cycle 1 by over achieving the target notified by 59%. The aluminium industries are upgrading themselves by adapting state-of-art technologies, which are more energy efficient and sustainable in a highly competitive market. As the demand of aluminium is going to rise in the coming years, there will be high volume generation of CO2 from the aluminium smelting process as well as from the captive power plants. Therefore, there is an urgent need to re-focus on environment friendly and energy efficient technologies/processes for delivering sustainable aluminium in a longer term.
Vote of Thanks was presented by Shri Jagannath Prasad Nayak, Head-Smelter, Hindalco Industries Limited, Hirakud. He conveyed his thanks to the dignitaries, speakers and delegates for their presence and participation in the workshop and assured the full support of Hindalco Industries Limited in future activities under KEP initiative.
Dignitaries at the inaugural session
The inaugural event was followed by five technical sessions and a panel discussion. The first technical session was focused on Perform Achieve and Trade scheme. Shri K K Chakarvarti, Expert Consultant, Bureau of Energy Efficiency presented the achievements and learnings from Perform Achieve and Trade (PAT) Cycle 1 and challenges of PAT 2nd Cycle, which covered success stories achieved under PAT 1 Cycle for Aluminium sector, information on the current status as well as the mandatory requirements to be fulfilled by DCs, key aspects of ESCerts trading scheme, impacts of PAT Cycle 1 and overview & challenges of PAT 2nd Cycle. He congratulated Aluminium Sector for achieving Specific Energy Consumption performance improvement from 5.52 to 5.04 toe/t product (8.7% improvement ) in Smelter plants & 0.328 to 0.306 toe/t product ( 6.7 % improvement) in Alumina Refinery in PAT Cycle-I.
Shri K K Chakarvarti delivering his presentation in the first technical session
The second technical session was focused on sharing of experience of the Aluminium Smelter and Power Plants, was chaired by Dr. Anupam Agnihotri, Director, JNARDDC. The presentation by JNARDDC explained the energy efficiency barriers in aluminium smelting. While explaining why aluminium smelting is not very energy efficient, he mentioned that the anode-cathode distance (ACD) is kept above a certain minimum to avoid back reaction of aluminium with CO2 which leads to high voltage consumption and heat losses are necessary to maintain a frozen side ledge to protect the sidewall which leads to wastage of extra heat. The presentation also explained the strategies to overcome these barriers viz. by reducing cell voltage, maximizing current efficiency and by preheating the anodes. The presentation by Hindalco Industries Limited, Renukoot explained the energy efficiency gains achieved by reducing the pot voltage at the Renukoot Smelter which led to a reduction in power consumption by 284kWh/t of aluminium. The presentation by Hindalco Industries Limited, Hirakud explained the power quality problems faced by the aluminium industries viz. transients, over voltage, under voltage, sag, swell, interruptions, voltage unbalance and harmonics and highlighted various ways through which these issues can be mitigated. The presentation by Vedanta Limited, Jharsuguda explained the energy efficiency achieved by implementation of slotted anodes which led to bath drop reduction and saving of 96 kWh/t of aluminium, opportunities that industry can avail to reduce the voltage consumption at cathode and strategies to improve thermal and magnetic balance. The presentation by Vedanta Limited, Captive Power Plant, Jharsuguda presented the energy efficiency projects implemented viz. isolation of SWAS grab sample, condenser cleaning through Jet, bullet & chemical, installation of refrigerant drier, fuel switching from HFO to LDO and CT Fans Blades Replacement that led to monetary savings of Rs. 0.9 million /year, Rs. 41.55 million, energy saving of 27kW/h and Rs. 19.1 million/year respectively.
Presentations being delivered by the panelists of the second technical session
The third technical session focussing on sharing of experience of the Aluminium Refineries on implementation of innovative best practices was chaired by Shri N Roy, Unit Head, Hindalco Industries Limited, Muri & Shri M J Chaddha, Sr. Scientist, JNARDDC. The presentation by Hindalco Industries Limited, Muri explained various steps to reduce the energy consumption in aluminium refineries viz. by improving the bauxite quality and liquor productivity, indirect heating of the bauxite slurry, single stream digestion, circulating fluidized bed calciner and falling film evaporator. The presentation by NALCO, Damanjodi explained that coal conservation by the use of Thermact, a combustion catalyst, which reduces fuel consumption by 2 to 5%, reduces unburnt in Bottom Ash & fly Ash, increases ash fusion temperature, reducing accretion in furnace, leading to monetary savings of Rs 1.56 million. The presentation by Vedanta Limited, Lanjigarh explained the energy efficiency gains achieved by installing energy efficiency lighting, capacitor bank and auto-drain valve that led to monetary savings of Rs. 0.279 million, Rs. 0.657 million and Rs. 0.72 million respectively.
Presentations being delivered by the panelists of the third technical session
The fourth technical session was focused on utilization of spent pot liner (SPL) in cement & steel industry – status, issues and way forward, was chaired by Shri K K Chakarvarti, Expert Consultant, Bureau of Energy Efficiency. Shri Chakarvarti informed the participants that this issue came up in the first SLG meeting of the Aluminium sector held in Bhubaneshwar on 20th June, 2015, wherein the issue of management of SPL with its possible use in some other sector was raised by Shri R K Gupta, Sr. President & Head-Sambalpur Cluster, Hindalco Industries Limited. The idea gained momentum in the cement SLG meeting held in Jodhpur on 22nd June, 2015, where SLG members from cement sector also showed keen interest in the subject. With both the sectors showing their commitment and intent, KEP thought of bringing the industry leaders, technology suppliers and regulators on a common platform to discuss it further. In line with this, policy roundtable on ‘promoting use of SPL in Cement Co-processing’ was organized on 22nd September, 2015 followed by the first Joint Task Force meet on 8th January 2016, where the subject was discussed. The presentation highlighted the key points of the discussions made during the above meetings. The net availability of SPL in India is about 32,000 tonne per annum (TPA): about 65,000 tonne of SPL is lying at NALCO Smelter Plant, 4000 – 5000 TPA at BALCO, 10,000 TPA at Vedanta Limited, 18000 TPA at Hindalco Industries Limited. He also highlighted the current practices and major challenges being faced for the disposal of SPL through co-processing. While sharing the trial outcome of use of SPL in a cement industry, the presentation by BALCO highlighted that the prepared clinker showed decrease in free lime in presence of SPL and acted as mineralizer and reduces the free lime in clinker substantially. The fluorine detected in clinker confirmed its assimilation as well as mineralizing effect and increases the C3S content in clinker. The carbonaceous content of SPL is well burnt at higher temperature and provides additional heat to the system. The results show that upto 2.0% SPL can be easily used as raw mix component without affecting the quality of clinker. The utilization of SPL in cement manufacturing not only offers saving of fuel and conventional raw material depletion but also provides solution to environmental problem created by disposal of SPL in plant area.
Presentations being delivered by the panelists of the fourth technical session
The fifth technical session was focused on energy efficient technologies for aluminium sector was chaired by Dr. Anupam Agnihotri, Director, JNARDDC. This session was planned in a manner that it brought together the technology providers and industry representatives with a view to promote interactions between the two stakeholder groups that can help in facilitating adoption of cleaner technologies. The session had presentations on technologies available for various processes in aluminium sector viz. energy efficient cooling Solutions through absorption technology by Thermax Limited, high efficient rectifier system by ABB India Limited, energy efficient GAMI technology, energy saving opportunities in aluminum plants by Forbes Marshall and energy efficiency in compressed air systems by Atlas Copco India Limited.
Dr. Agnihotri with the panelists of the fifth technical session
Technical sessions was followed by a discussion on technology gap assessment in which Shri Debasish Ghosh, AVP – Hindalco Technology (Energy), Hindalco Industries Limited shared the waste heat recovery (WHR) opportunities available for Aluminium industries. He mentioned that although the waste heat is abundant, current usage in primary aluminum facilities remains limited. This is due to both the low quality of waste heat available and the shortage of potential uses within reasonable distance of identified waste heat sources. He informed that about 19.2 % of electrical energy used in a smelter plant is carried away by exhaust gas and about 20.8 % by Shell dissipation. These hot gases can be used to heat water to 75 Deg. C which can be further used in vapour absorption machine to generate chilled water for air conditioning of control room.
On behalf of Bureau of Energy Efficiency and Institute for Industrial Productivity, Shri K. K. Chakarvarti thanked the top management of Hindalco Industries Limited, Hirakud in particular, Shri R. K. Gupta, Sr. President & Head-Sambalpur Cluster; Shri Jagannath Prasad Nayak, Head-Smelter and the entire team of Hindalco Industries Limited for extending their earnest support to the KEP initiative and pulling through an event of this scale. He also conveyed his sincere thanks to Dr. Anupam Agnihotri, Director, Jawaharlal Nehru Aluminium Research Development and Design Centre (JNARDDC), Shri N Roy, Unit Head, Hindalco Industries Limited, Muri and Shri MJ Chaddha, Sr. Scientist, JNARDDC and Shri Debasish Ghosh, AVP – Hindalco Technology (Energy), Hindalco Industries Limited for their presence and sharing their experience with the participants at the workshop. He also thanked all the speakers and delegates who participated in the workshop and thanked them for their comments and suggestions and assured that each will be given consideration so that future workshops will be even more of a success.
The workshop had participation from over 100 eminent aluminium industry leaders’, Odisha State Designated Agency (SDA), technology providers, distinguished speakers, energy managers and auditors, and senior Industry professionals amongst many others.
Participants at the 2nd Aluminium sector Workshop under Knowledge Exchange Platform initiative
The field visit to Hindalco Industries Limited, Hirakud was organized on 17th December, 2016 which was attended by 60 officials from Aluminium Industry. Delegates were taken around the Smelter Plant, Captive Power Plant and Hirakud Dam. This industrial visit facilitated interaction with the plant personnel on energy efficiency improvement initiatives, maintenance practices, efficient operation and monitoring practices.
Delegates at the Plant visit to Smelter and CPP plant
At the conclusion of plant visit, delegates thanked the management of Hindalco Industries Limited and congratulated the initiative taken by Knowledge Exchange Platform for organizing the Two Days’ workshop and plant visit for the benefit of industry.
2nd WORKSHOP AND FIELD VISITS BEST PRACTICES IN ENERGY EFFICIENCY IN ALUMINIUM SECTOR
INAUGURAL SESSION (9.15 AM- 10.00 AM)
Lighting of Lamp
Welcome Address, introduction and strategies for the next phase of KEP initiative Shri K. K. Chakarvarti , Expert Consultant, Bureau of Energy Efficiency
Special Address Dr. Anupam Agnihotri, Director, Jawaharlal Nehru Aluminium Research Development and Design Centre (JNARDDC)
Inaugural Address Shri R. K. Gupta, Sr. President & Head-Sambalpur Cluster, Hindalco Industries Limited
Vote of Thanks Shri Jagannath Prasad Nayak , Head-Smelter, Hindalco Industries Limited, Hirakud
TEA BREAK (10.00AM -10.15 AM)
TECHNICAL SESSION I (10.15 AM – 10.35 AM): Perform Achieve and Trade Scheme
Overview of PAT 1 and PAT 2nd Cycle by Bureau of Energy Efficiency Shri K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency
TECHNICAL SESSION II (10.35 AM – 12.00 PM): Sharing of Best Practices from Aluminium Smelter and Power Plants
Chairman Dr. Anupam Agnihotri, Director, JNARDDC
The Energy Efficiency Barrier in Aluminium smelting Dr. Anupam Agnihotri, Director, JNARDDC
To Reduce Pot Voltage at Renukoot Smelter to Enhance Energy Efficiency Shri Vibhav Upadhyay, Tech Head Reduction Plant
Shri Anuj Kumar Verma, Manager
Shri Vivek Agrawal, Energy Coordinator (I E & Tech Cell), Hindalco Industries Limited, Renukoot
Harmonics & Power System & its Mitigation Shri Nimai Charan Mohapatra, GM, EMD& C&I - Power Plant, Hindalco Industries Limited
Energy For Aluminium, Past, Present and Future Shri Bijneswar Mohanty, Associate Vice President, Smelter
Shri Hitesh, Manager, Smelter, Vedanta Limited, Aluminium Business
Excellence in Energy Management in Captive Power Plant Shri Ajay Pande, GM Operation, Captive Power Plant
Shri Pravupada Acharya, Assistant Manager, Vedanta Limited, Aluminium Business
TECHNICAL SESSION III (12.00 PM – 1.10 PM): Sharing of Best Practices from Aluminium Refinery
Chairman Shri N Roy, Unit Head, Hindalco Industries Limited, Muri & Shri M J Chaddha, Sr. Scientist, JNARDDC
Energy Efficiency in Alumina Refinery Shri N Roy, Unit Head, Hindalco Industries Limited, Muri
Sharing of JNARDDC experience in energy efficiency improvement in Alumina Refinery Shri M J Chaddha, Sr. Scientist, JNARDDC
Coal conservation by use of Combustion Catalyst Shri S. S. Mishra, NALCO Damanjodi
Shri D. Shrivastava, NALCO Damanjodi
Energy initiatives at Vedanta-Lanjigarh Shri Hemant Kumar Sahoo, Manager- Maintenance, Vedanta Limited, Lanjigarh
TECHNICAL SESSION IV (2.00 PM – 2.45 PM): Utilization of Spent Pot Liner in Cement & Steel industry – Status, Issues and Way forward
Chairman Shri K K Chakarvarti, Expert Consultant, Bureau of Energy Efficiency
Opportunities to use SPL- A hazardous waste Shri K K Chakarvarti, Expert Consultant, Bureau of Energy Efficiency
SPL utilization in Cement & Steel Industries Shri Nitin Tiwari, AGM ,Head Planning & Waste Management
TECHNICAL SESSION V (2.45 PM – 5.00 PM): Innovative and effective Technologies for promoting energy efficiency in the Aluminium Sector
Chairman Dr. Anupam Agnihotri, Director, JNARDDC
Energy Efficient Cooling Solutions through Absorption Technology Shri Debasish Mukherjee, Domestic Sales, Thermax Limited
High Efficient Rectifier System Shri Vijayaprasad C, Vice President-Project Management, ABB India Limited
Energy Efficient GAMI Technology Shri Xie Zhuojun, GAMI Technology, China
Energy Saving Opportunities in Aluminum Plants Shri Pankaj Kumar Srivastava, Regional Manager, Forbes Marshall
Energy Efficiency in Compressed air systems Shri Sumeet Kumar Das Adhikari, Sr. Sales Engineer, Atlas Copco India Limited
PANEL DISCUSSION (5.00 PM – 5.20 PM) : Technology Gap Assessment- Mapping the present status of Aluminium industry in terms of EE technology deployment and the need of technological advancement in order to achieve the targets set under the 2nd cycle of PAT.
Waste Heat Recovery and Renewable Energy Projects in Aluminium production - Opportunities & Challenges Shri Debasish Ghosh, AVP - Hindalco Technology (Energy), Hindalco Industries Limited
CONCLUDING REMARKS (5.20 PM - 5.30 PM)
Shri R. K. Gupta, President, Hindalco Industries Limited, Hirakud
Dr. Anupam Agnihotri, Director, Jawaharlal Nehru Aluminium Research Development and Design Centre
Shri K. K. Chakarvarti , Expert Consultant, Bureau of Energy Efficiency
17th December 2016: Field Visit
9.00am-11.00am Area of Visits
· Hindalco Smelter Plant
· Hirakud Captive Power Plant
11.00am-1.00pm Nearby historic sites like Hirakud Dam (longest major earthen dam in India, measuring 25.8 km including dykes, and stands across the river Mahanadi).
1.00pm - 1.30pm Concluding Remarks and feedback from participants
1.30pm – 2.30pm Lunch Break and Close