cii national award for excellence in energy management ... · integrity commitment passion...
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CII National Award for Excellence in Energy Management 2020
Hindalco Industries ltd.Unit : Mahan Aluminium,Singrauli (MP)
Team – Mr S. Roy ChowdhuryMr. SP Singh Mr. Binay KulluMr. Anand Swami
Integrity Commitment SpeedPassion Seamlessness2
Company profile –ABG Hindalco
RENUKOOT
RENUSAGAR
HIRAKUD
MURI
BELUR
MOUDA
ALUPURAM
BELGAUM
TALOJA
We are
Here
Current Capacities (KTPA)
Alumina: 3,000
Metal: 1,330
FRP: 360
Extrusions: 60
Foils: 17
Captive Power ~3200 MW
Copper: 500
DAHEJ
ADITYA
UTKAL
MAHAN
Alumina
Primary
Power
Rolled
Foil
Extrusions
R&D
Copper
About the Group:
Aditya Birla Group is US $44 Billion corporation in the fortune 500 league. And a 4th in the world & 1st in the Asia Pacific “Top Companies of Leaders” ‘The group is anchored by an extraordinary work force of over 120,000 Employees, Spread in 42 countries
About Hindalco:
Hindalco Industries Limited ,Metals flagship company of the Aditya Birla Group , is the industry Leader in Aluminium & Copper with a consolidated turnover of US $17 Billion
About Mahan Aluminium:
Hindalco Industries ,Mahan Aluminium is a Greenfield Aluminium Plant in the State Madhya Pradesh. Consisting of a 3.59 lakh ton Smelter Plant with 900 MW Captive Power Plant (applicable Unit).
Mahan has achieved ISO certification in 2016 & confirming to ISO 9001:2015, ISO 14001:2015 certification in the year 2018 .Listed in London Metal Exchange in 2016. Also got certification in ISO 50001:2018 & ISO 45001:2018 last year 2019.
Integrity Commitment SpeedPassion Seamlessness3
About Us- Mahan Complex
Coal Based Captive Power Plant:( 6 X 150 MW):
The plant consists of state of the art Smelter unit ( 360 pots – Aluminum Pechiney AP 36 technology AP-36 ). An uninterrupted power supply for the Aluminiumplant, Power plant auxiliary & for the colony etc., 750 MW capacity of the power plant was assessed. Being Aluminum industries highly energy intensive unit, it is necessary to make available standby capacity to meet the exigency and as such the plant is configured as 5x150 MW + 1x150 MW i.e. a plant of 900 MW
Technology Partners
(First unit was synchronized on 9th March 2013)
Our vision :To be a premium metals major, global in size and reach, excelling in everything we do, and creating value for its stakeholders.ch, excelling in everything we do, and creating value for its stakeholders
Our mission :To relentlessly pursue the creation of superior shareholder value, by exceeding customer expectation profitably, unleashing employee potential, while being a responsible corporate citizen, adhering to our values. citizen, adhering to our values
Integrity Commitment SpeedPassion Seamlessness4
Energy Management System – Approach
Unit Objective - To achieve specific energy target – 159.84 GJ/MT , 16.24 tCo2/t , 3.83 TOE/t
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Among Hindalco, Mahan is 1st unit to achieve ISO 50001-2018 certificate FY 20-21
a. GJ/T:-159.84b. tCO2/t:-16.24c. TOE/T:-3.83
FY 19-20 (Achieved)a. GJ/T:-160.29b. tCO2/t:-16.35c. TOE/T:-3.83
Carbon
Foot
Integrity Commitment SpeedPassion Seamlessness5
Energy Balance & Mapping Mahan Unit – EMS
An Energy intensive Unit having the energy tracking & monitoring system from plant GATE IN to GATE OUT . It widely covers all the process of Smelter ,Power & other form of energy consumption
Mahan has earned 18312 e- Certificate in PAT-II cycle.
B. Energy Conversion of Raw Material to 1 MWh C. Unit- Energy Mapping
A. Energy Balance – Captive Power Plant
Particulars UOMFY-20
(Upto July)FY-21
(Upto July)
Coal Mkcal 4801944 4424025
HSD Mkcal 319 188
LDO Mkcal 4388 1954
Total Energy Mkcal 4806652 4426167
Gross Generation Lakh Unit 18799 17693
Gross Heat Rate Kcal/kwh 2557 2502
Integrity Commitment SpeedPassion Seamlessness6
Mahan CPP – Performance Trend A. Auxiliary power Consumption B. Specific oil Consumption C. Boiler Efficiency
A. APC Initiatives• No of mill operation reduced from 4 to
3 as per coal fed rate in boilers resulted 280 kW per mill in each unit.
• Operation of 3 pumps between 2 units• Throttling loss in TGs reduced • Optimizing ash plant compressors
operation based on cycle time.• Increasing coal feed factor of CHP
conveyors
B. Specific Oil Consumption
• Reduction in unit startup time
• Improving oil gun availability
• Unit start up with hot water flushing
• Ensure air blaster healthiness of coal
bunkers rainy seasons
• Periodic Coal bunker cleaning
• Covering coal heaps during monsoon
C. Boiler Efficiency
• Reduction in Dry flue gas losses
• Reduction in Unburnt losses
• Reduction in Mill reject losses
• Reduction in cycle make up
7.66 7.67
7.53
7.28
7.00
7.10
7.20
7.30
7.40
7.50
7.60
7.70
7.80
FY 17-18 FY 18-19 FY 19-20 FY 20-21
0.445
0.258
0.1500.121
0.000
0.050
0.100
0.150
0.200
0.250
0.300
0.350
0.400
0.450
0.500
FY 17-18 FY 18-19 FY 19-20 FY 20-21
86.59
86.25
86.8386.95
85.80
86.00
86.20
86.40
86.60
86.80
87.00
87.20
FY 17-18 FY 18-19 FY 19-20 FY 20-21
Integrity Commitment SpeedPassion Seamlessness7
Mahan CPP – Performance Trend D. PLANT HEAT RATE
2396
2406
2409
2420
2380 2385 2390 2395 2400 2405 2410 2415 2420 2425
FY 17-18
FY 18-19
FY 19-20
FY 20-21
Gross Heat Rate in Kcal/kwh
2655
2655
2655
2655
2595
2606
2605
2613
2560 2570 2580 2590 2600 2610 2620 2630 2640 2650 2660
FY 17-18
FY 18-19
FY 19-20
FY 20-21
Net Heat Rate in kcal/kwh
Act. Net HR Design Net HR
Reason For Deviation:
• Inaccurate measurement of main steam flow • Partial load loss due to reduced smelter demand.• Deterioration in vacuum.• Deterioration in Feed Water Heater Performance• Increased APH leakage (Boiler overhauling delayed)
Challenges:
• Reliability of Belt Weigher readings of coal fed conveyors
• Consistent Coal Quality on sustainable basis, Error in sample collection & preparation
• Coal Reconciliation ( Energy Balance between Receipt & Fed coal)
Integrity Commitment SpeedPassion Seamlessness8
Mahan CPP – Performance Trend
70.19 70.2270.78
67.14
65.00
66.00
67.00
68.00
69.00
70.00
71.00
72.00
FY 17-18 FY 18-19 FY 19-20 FY 20-21
2.387
2.467
2.502
2.525
2.300
2.350
2.400
2.450
2.500
2.550
FY 17-18 FY 18-19 FY 19-20 FY 20-21
0.810.77
0.60 0.60
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
FY 17-18 FY 18-19 FY 19-20 FY 20-21
85.41
93.69 93.66
96.04
78.00
80.00
82.00
84.00
86.00
88.00
90.00
92.00
94.00
96.00
98.00
FY 17-18 FY 18-19 FY 19-20 FY 20-21
A. Plant Load factor (%) B. Plant Availability factor (%)
C. Raw Water Consumption (ltrs/kwh) D. DM Water Consumption (%)
A. PLF low due to low smelter demand
Highlighter
B. PAF increased due to improved maintenance practices
C. Raw water consumption was side due to various underground leakages. Attended in April’20. Raw Water consumption reduced (May’20- 2.453, Jun’20-
2.450, July’20- 2.380 )
D. Cycle make up has improving trends
Integrity Commitment SpeedPassion Seamlessness9
Benchmarking for 150 MW for FY 20
LOCATIONN UOM ADITYA MAHAN
Plant Heat Rate (On coal Booking) Kcal/kwh 2472 2453
Turbine Heat Rate Kcal/kwh 2061 2069
Boiler Efficiency % 85.82 86.83
APC % 7.81 7.53
Specific Oil consumption ml/Kwh 0.20 0.15
Mill Reject quantity kg/MW 35 9
Cycle Make up % 0.80 0.60
Dry flue gas Loss % 3.01 4.82
Unburnt Carbon Loss % 1.35 0.27
Boiler tube leakage Nos 5 1
Hindalco has a unique platform to compare the best practice with the sister plant Aditya Sambalpur, Orissa. The practices of comparing the processes, performance metrics and the best practices shared on monthly basis.
Comparison
Best Practices Sharing
Integrity Commitment SpeedPassion Seamlessness10
Best Practices – Operational Excellence
• Reduction in Boiler tube leakages to almost ZERO by ensuring 100% RT ofweld joints and application of Plastic Refractory in burner area.
• Effective Coal Management and Accounting of coal being done by Dronesurvey on weekly & Total Station survey on monthly basis. Belt weigheraccuracy is also ensured through Fortnightly Drop Test with Wagons / coaltrucks.
• 100% PM & CBM Compliance leading to ZERO critical equipment in REDZONE since last 1 year. Also load reduction near to ZERO due to equipmentoutage.
• Special Specific Oil reduction programme
• Reduction in Auxiliary Power Consumption by optimizing the operationalprocedures
• Reduction in rake unloading time led reduction in demurrage charges
• Effective Load Management of unit in islanded condition helped in operatingour station for 8.5 days.
5R – Concept
Integrity Commitment SpeedPassion Seamlessness11
Best Practices – Maintenance
Tools & Techniques Adopted:-
a) PM Compliance monitoring
b) CBM- Vibration Analysis, Oil Analysis, Motor Current Signature Analysis, Thermography.
c) Electrical- Tan Delta & Capacitance of CT & Transformer Bushings, Third Harmonic Resistive Current(THRC) Test of Lightning Arrestor(LA)Transformer Oil BDV & DGA,ELCID, PD, Tan Delta, RSO for generator.
d) Non Destructive Testing- 100% Radio Graph Test, Helium Leak Test Air Leak Test.
a) Inventory Management System
CT Water Temp. MappingCoal Heap
Motor Current Signature Analysis
72
8999
60
110
FY'19 FY'20 FY'21
PM Compliance %
9699 100
90
95
100
105
FY'19 FY'20 FY'21
CBM Compliance %
Integrity Commitment SpeedPassion Seamlessness12
Digitalization
FY -17 to19
A. GSM based Wireless system(Fig.-1) for CT fan Vibration & oil level measurement commissioned for U#1 & 2.
B. Radio frequency based Wireless system commissioned for CCRD of Stacker # 1
C. Automation initiatives under Digitalization
D. On line Energy Monitoring system
FY-20
A. KPI Tracking Dashboard
B. KPI Tracking on Mobile APP
C. Coordinated Master Control-In progress
D. Real time data from BW weightometer to remote server
E. Energy Management System (EMS) implemented in CHP and AHP
FY-21
A. Coal Supply chain tracking system
B. Online Lab information management system
C. Centralized data acquisition system of the plant
D. Ekyayan Project- Centralized ERP system
E. Scope-3 Emission calculation project-Jointly with Smelter
Hindalco Mahan embarked on its digital transformation journey, Digital is data, start small & keep the focus on, Mapping technology for the future & managing change at people level.
Integrity Commitment SpeedPassion Seamlessness13
Energy saving projects implemented in last 3 years
Year No. of
proposalsElectricity
(Lakh KwH)Thermal (Rs. In
Millions)Savings
(Rs in millions)Investment
(Rs in Lakhs)Payback Months
FY 17-18 8 2.93 5.74 6.67 20.05 3
FY 18-19 4 31.86 0 11.18 84.4 2
FY 19-20 13 142.49 90.12 135.13 102.00 2
Total 23 177.29 95.86 152.98 187.5
Year No. of proposalsElectricity
(Millions KwH)Thermal
Savings (Rs in millions)
Investment (Rsin Lakh)
Payback Months
FY 20-21 12 25.41 0 56 60.5 3
Total 12 25.41 0 56 60.5 3
Integrity Commitment SpeedPassion Seamlessness14
Energy saving projects implemented in FY 17-20FY 17-18
1. Replacement of conventional HPSV well glass fitting with LED light2. Installation of occupancy sensor3. Operation of Heat Of Compression drier4. Reduce power consumption in air compressor by pressure reduction5. Improvement in PHR after overhauling of units6. Radiation loss reduction due to Insulation improvement in Boiler 4 & 6 7. Voltage optimization in plant illumination circuit8. Use of astronomical timer for street light control
FY 18-19
1. Installation of Medium Voltage VFD in CEP-B of Unit-62. Replacement of Cooling tower blade from GRP to FRP in CT-1 &CT-23. Installation of VFD in CT make up pump4. Installation of VFD in Potable Water Pump
No. of projects :- 8
Saving in lakh Kwh:-2.93
Total Savings in Million Rs :-6.67
No. of projects :-4
Saving in lakh Kwh:-31.86
Total Savings in Million Rs :-11.18
Integrity Commitment SpeedPassion Seamlessness15
Energy saving projects implemented in FY 17-20FY 19-20
1. Increased in Boiler Eff. By 0.58% & PHR by 15.08 kcal/kwh 2. Reduction in specific oil consumption 0.454 ml/kwh to .011
ml/kwh.3. Replacement of Cooling tower blade from GRP to FRP in CT
4. No of mill operation reduced from 4 to 3 as per coal fed rate in boilers
5. Operation of 3 CW Pumps between 2 Units6. Reduction in Ash Plant Compressor energy Consumption by
Optimizing Cycle time.7. Throttling loss in TGs reduced 8. Flue Gas Duct Modification carried out in Unit-2 as per CFD
analysis9. Increasing coal feed factor of CHP conveyors10. Conveying Path modification in Coal Handling Plant11. Stoppage of Unit & Station ACW pump in low load operation 12. Optimization of DM Makeup pump and Service water Pump
Operation13. Reduction of CEP Header Pressure from 18 to 11.5 Kg/cm2
No. of projects :-14
Saving in lakh Kwh:-142.29
Total savings in Million Rs :-135.13
Integrity Commitment SpeedPassion Seamlessness16
Energy Saving Projects planned in FY 21
No. of projects :-12
Saving in lakh Kwh:-25.41
Investment in Rs lakh:-67.5
Challenges & Support Required:
• Training and Awareness• Bench marking on India & World• Digitalization & New Technology being adopted in other plants• Sharing of best practices
FY 20-21 (Planned)
1. Replacement of conventional HPSV well glass fitting with LED light2. Installation of occupancy sensor3. Arresting air leakage & Optimizing no. of Compressors (Inst & service air)4. Pressure optimization of ash handling compressors 5. CW Pump impeller modification6. Voltage optimization in illumination circuit7. Replacement of Cooling tower blade from GRP to FRP in CT8. Use of astronomical timer for street light control9. Optimization of LP pump operation10. Use of VFD in Seal Air, TAC, Slurry Pump ,Service water pump.11. Improvement in PHR – Vacuum, TG System losses etc12. BW Reliabity & Coal quality improvement by CSCTC
Integrity Commitment SpeedPassion Seamlessness
Result :
1. Net energy saved 42.3 Lakh Kwh
2. Savings/Year- 2.747 Rs Million
2292
3304
1381
760
-300
700
1700
2700
3700
ESP MRS
Cyc
le C
ou
nte
r
Conveying Cycle FY18-19 & FY19-20
Average/Day
Cycle FY18-19 Cycle FY19-20
126
63
104
55
0
50
100
150
Compressor RH Energy(MWH)
Running Hour & Energy
Average/Day
FY18-19 FY19-20
18.33
14.58
3.75
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
16.00
18.00
20.00
FY 18-19 FY 19-20 Variance
Average for Six Months
Specific Energy Consumption (Kwh/MT)
Project 1 -Reduction in Compressor SPC by Conveying Cycle Optimization
17
In Ash Handling Plant, fly ash conveying & MRHS System was operated in Timer Mode since commissioning . After changeover from Timer Mode to Probe Mode savings listed in graphs.
The savings observed in conveying cycle, running hours & specific power consumption.
Integrity Commitment SpeedPassion Seamlessness
CPP Project 2- Reduction in Dry Flue Gas lossesProjects Details :
Reduction in Dry flu gas losses from 5.47 % to 4.95 % . And resulted in 0.52 % improvement in Boiler efficiency & PHR by 15 Kcal/kWh.
A. FY- 20 After Sep-19 to Mar-20 Boiler Losses due to DFG – 4.72 % .
B. FY – 21 Reduction in Losses due to DFG- 4.45 % (April-Jul’20).
5.27 5.10 5.16 4.95 4.92 4.78 4.84 4.59 4.55 4.41 4.31 4.43 4.54 4.52
0.00
1.00
2.00
3.00
4.00
5.00
6.00
After
19
5.45
5.73
5.4 5.36 5.415.49
4.5
4.7
4.9
5.1
5.3
5.5
5.7
5.9
Dec-18 Jan-19 Feb-19 Mar-19 Apr-19 May-19
% L
oss
du
e t
o D
ry F
lue
Ga
s
Before
Integrity Commitment SpeedPassion Seamlessness
CPP Project 2- Action Taken to reduce Dry Flue gasloss
Action Taken:-
1. 100% availability of Soot blowers.2. APH leakage arrested 3. Optimization in Excess Air4. Improvement by plugging gaps in between
baskets and Basket-diaphragms 5. APH hot washing
20
Integrity Commitment SpeedPassion Seamlessness
Project -3 PHR Improvement through Online Chemical Cleaning of CT Fills
Chemicals used for online fills cleaning:
1. LABS-Linear Alkyl Benzene Sulphonate(Surfactant/Detergent)
2. Ter Polymer (Polymeric Dispersant)
3. EDTA-(Chelating Agent for Hard Scale removal)
4. Sodium Hypo chlorite (Oxidizing biocide)
5. Chlorine Dioxide (Oxidizing Biocide) 6. Sulphuric Acid (For pH Reduction)
7. Maxtreat 7002A (Bio dispersant)
8. Caustic Soda Lye( pH Booster)
Before Cleaning Online Cleaning After Cleaning
Improvement in PHR due to Online Cleaning
Description UOM Before After Gain/Loss
VacuumKg/cm2 0.1115 0.0958 0.0157
mmHg 82.04 70.47 11.57
Improvement Before & After Treatment 23.13 kcal/kwh
21
Projects: Poor vacuum leading to deterioration in overall Plant Heat rate .
Action : Improvement in PHR due to online cleaning of chemical cleaning of cooling tower fills.
Integrity Commitment SpeedPassion Seamlessness
Furnace
Drum
Thermal Expansion
Economiser
LTSH
Pent house
Pent house top
Free Expansion of Supports
Modification in Pent House refractory to Protect Supports
1. Cracks in Refractory
2. Ash Accumulation at Pent House
3. Heat Loss4. Water Seepage in Pent House5. Damaged Support
Innovation Project-1 : Boiler Reliability Enhancement
22
Integrity Commitment SpeedPassion Seamlessness22
Application of Plastic refractory in Burner panels, LCT, UCT
Erosion of tubes
Plastic Refractory
Plastic Refractory
Provision of J- Plate on Coal nozzle .
First unit to Implement plastic refractory & J –plate on coal nozzle among Hindalco Units
Innovation Project -2 : Boiler Reliability Enhancement
Total Net Avg. Saving /BTL = 23 Lakhs , MTBF is significantly increased & Aluminum Production loss 60MT/Day is saved
Integrity Commitment SpeedPassion Seamlessness
Kaizen
Mahan CPP has got special jury award for participation in 36th kaizen competition arranged by CII team on 24-25th Feb’20.
Title:-Availability of Main Steam Sample at the time of Boiler Cold Start-up.
Year YTD Kaizen / EmployeeKaizen Participation
Index (YTD %)
FY -20 2252 8.31 100
FY -21 1467 3.76 65.90
Salient Features:-
• No. of Small Groups – 21 nos.• Digitization of kaizen reporting • Monthly Monitoring on kaizen projects• Reward & recognizitaion –Unit ,Cluster & Group level
Kaizen Details:-
26
Integrity Commitment SpeedPassion Seamlessness
Kaizen Case Study:- Damage of PCRD Cable of stacker reclaimer During Feeding/stacking.
Cable Rubbing with the BeamAdditional Idler Provided to prevent Rubbing of cable with Beam
PCRD Cable
Beam
After
Problem:-During regular operation of Stacker, failure of incoming power supply due to rubbing of power cable with it’s structural support beam while moving along with stacker movement.
Intangible gain:
1) Enhancing the availability of Stacker for Stacking from Rake/RH and to feed the coal in bunkers.
2) Safe operation of machine.
Before
Tangible gain:
1) INR 55000/- approx. (repairing of damaged cable), 2) INR 8 Lakhs approx. (for new cable replacement if multiple times cable damaged)
26
Integrity Commitment SpeedPassion Seamlessness25
Ash Utilization
Salient Features:-
• Long term agreement with M/s. Prism cement and Ultratech cement.• Ash utilization in land reclamation and road construction• Ash utilization in brick plant .
FY-21 Way Forward:-
• Approval of 12Lakh MT for filling in land reclamation inside of plant is in process.• Approval of 16Lakh MT for filling in land reclamation outside of plant.• Capacity to make- 30000 Nos brick per day –FY-21
Particulars UOM 2017-18 2018-19 2019-20
CO2 emission /kw T/Kw 1.10 1.03 1.01
Ash Generated Tons 1259173 1258003 1296699
Ash Utilization % 50.27 72.89 67.66
Ash Utilized in manufacturing of cement/concrete – other similar products
% 44.91 71.80 63.05
Ash Utilized for Roads pavements % 5.36 11.66 4.61
Integrity Commitment SpeedPassion Seamlessness26
Environmental Performance
Particulars UOM Stack no 2017-18 2018-19 2019-20
Current SOxEmissions at
Full Load*
mg/Nm3
UNIT-1 397.31 407.6 349.96
UNIT-2 420.1 451.2 386.15
UNIT-3 532.2 444.9 370.21
UNIT-4 533.2 442.2 368.78
UNIT-5 517.18 455.85 347.01
UNIT-6 527.86 459.83 396.6
Particulars UOM Stack no 2017-18 2018-19 2019-20
Current NOxEmissions at Full
Load*mg/Nm3
UNIT-1 166.69 217.5 214.98
UNIT-2 161.48 201 219.65
UNIT-3 229.19 228 235.58
UNIT-4 252.94 219.6 235.36
UNIT-5 235.69 231.49 199.43
UNIT-6 253.53 233.64 264.25
Particulars UOM Stack no 2017-18 2018-19 2019-20
Particulate Matter *mg/Nm3
UNIT-1 28.42 38.8 44.23
UNIT-2 28.42 35.6 39.18
UNIT-3 30.2 36.7 38.11
UNIT-4 36.17 37.5 36.7
UNIT-5 32.76 40.2 45.14
UNIT-6 31.7 37.9 30.98
Particulars UOM Stack no 2017-18 2018-19 2019-20
Mercury* Mg/Nm3
UNIT-1 BDL BDL BDL
UNIT-2 BDL BDL BDL
UNIT-3 BDL BDL BDL
UNIT-4 BDL BDL BDL
UNIT-5 BDL BDL BDL
UNIT-6 BDL BDL BDL
A. Sox Emission FY -18 to FY-20 B. Nox Emission FY -18 to FY-20
C. SPM Emission FY -18 to FY-20D. Mercury Emission FY -18 to FY-20BDL : Below detection level
Integrity Commitment SpeedPassion Seamlessness
Emission Control – Projects
27
A. Project – Suspended Particulate Matter (mg/Nm³)
B. Project – De- Nox(mg/Nm³)
C. Project – Flue gas Desulphurization (mg/Nm³)
Purpose: To Control the spmbelow 50 mg/Nm³
Technology : High frequency three phase transformer & Micro pulse
Target Commissioned : Dec’21 Target Emission: 50 mg/Nm³
Status: On Going
Purpose: To control the Noxbelow 290 mg/Nm³ @ 6 % O₂
Technology : The new combustion system consists of new Burner tips and Separate Over Fire Air (SOFA) system.
Target Commissioned : FY 21
Status: One Unit Completed
Purpose-To Control the Sox level below 600 mg/Nm³
Technology :Semi Dr Flue gas Desulphurization system
Target Commissioned –FY 22 ,Target Emission:- 600 mg/Nm³
Status : Soil Testing started for one Unit
Technology Suppliers
Integrity Commitment SpeedPassion Seamlessness
Renewable Power – Projects
28
Project – Renewable Solar Power - 35 MW
Purpose: Technology : Solar Energy Photovoltaic cell
Target Commissioned: May ‘21
Status: Land Approval under progress, IM filled ,Vendor visit started
Technology (Electrical) Type of Energy Installed Capacity (million kCal)
Usage (million kCal) % of overall thermal energy
Electrical Solar Energy NA NA
Integrity Commitment SpeedPassion Seamlessness
Sustainability Strategy
Business goals and Sustainability goals are shared
regularly
Monthly Energy Webinar for metal Business
Monthly performance review at Corporate level
Participation in Biennial ABG Energy Stride
Competition
Participation in annual ABG Sustainability
Conference
Awareness and Training
Annual Energy Conservation Day celebrations on
14th December every year .
Training on PAT cycle
Training on Energy Conservation Measures &
projects
Awareness program on ABG Energy and Carbon
policy
Young engineers encouragement for Energy
Auditors / Managers certification examinations.
Mahan has aligned its Sustainability Strategy with the group’s sustainability matrix.
Competitive Environment• PRIDE Awards
Employee of the month award at supervisory level
Instant Shabashi award at Supervisory level
Quarterly Kaizen Competition at workmen level
Best Small Group Awards at Staff & workmen level
Award for contractual workmen on Independence
& Republic day
Awareness & Development
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Integrity Commitment SpeedPassion Seamlessness
Mahan Unit has define the short & long term goals, which is linked with the business strategy, risk &
sustainability .
Unit Goals- Way Forward
Short Term Goal
• Continual improvement in operation & process – (3C+ 2S concept)• Focus on operational cost • Implementation of Renewable Energy Solar Project.• Implementation of Emission control projects- Sox, Nox & FGD.• Maximize participation in BEE exam to develop EM & EA.
Long Term Goal
• 100% utilization of Ash.• Continuous focus on training & skill development measures• Coverage of Digitalization at all Plant areas .
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Thank You
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