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First Prize

Aluminium

SESA STERLITE LIMITED

Smelter Plant - 1, Jharsuguda (Odisha)

Unit Profile

Sesa Sterlite Limited (SSL) Jharsuguda is a leading producer of aluminium products

such as ingots, wire rods and billets, which cater to a wide spectrum of industries.

The firm operates a 0.5 million TPA Aluminium Smelter Plant - 1 and 1215 MW

Captive Power Plant supported by highly modern infrastructure at Jharsuguda,

Odisha. In addition to this, commissioning of 1.25 million TPA Aluminium Smelter –

II expansion project at Jharsuguda has commenced.

In its pursuit to achieve energy excellence and to meet PAT targets set by Govt. Of

India, unit also successfully implemented Energy Management System (EnMS) and is

certified for international standard ISO: 50001 since Feb’2013.

Highlights of Energy Conservation Initiatives

� 1st Aluminium Smelter in Asia and second in world to be certified with ISO:

50001 for Energy Management System since 2013.

� 35 nos. of energy saving projects have been implemented in the last four years

generating saving of nearly 200 kWh/MT of aluminium production creating

national benchmark.

� SSL, Smelter - 1 is a trend setter to adopt ‘Reverse Osmosis’ for de-fluoridation

of waste water with evaporation of RO rejects in solar ponds. This is unique &

first of its kind in any Aluminium Plant to go for renewable energy in ETP in a RO

plant.

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� SSL has successfully completed carbon foot print study by independent external

agency First Climate and has taken a target to reduce CO2 emission by 5% from

baseline year FY 2012-13 by FY 2014-15. SSL has already achieved 2.3%

reduction in CO2 emission reduction from baseline 2013-14.

� Incorporation of Business Excellence models such as Six Sigma, QC, Kaizens,

SGAs and Asset Optimization in energy management. People involvement and

sharing best practices, internal & external benchmarking.

Energy Consumption

DESCRIPTION UNIT 2012-13 2013-14

Annual production MT 5,26,612 5,42,496

Total electrical energy consumption/annum M kWh 7,768 7,870

Specific energy consumption (electrical) kWh/MT 13,762 13,563

Total thermal energy consumption M kCal 1,82,229 1,62,469

Specific energy consumption (fuel) M kCal/MT 0.35 0.30

Energy Management System (ISO: 50001) Implementation

As a responsible corporate SSL, Jharsuguda is continuously strengthening the

energy management efforts for not only achieving PAT targets but also establishing

benchmarking figures in energy performance. As per the potential of opportunity for

improvement, target has been set for each Energy Performance Indicator (EnPI) and

accordingly action planning has been done to achieve the same. All the EnPIs are

mapped to employee’s KRA for ensuring implementation of the EnMS at each level.

MAJOR ENERGY SAVING PROJECTS IMPLEMENTED & INITIATIVES

TAKEN (2013 – 14)

1. Modification in cell lining design to achieve improvement in energy

efficiency in aluminium smelting

The cell lining deign of pots has been changed which has reduced the cathode

voltage drop and hence energy saving. The following technical inventions were

introduced to cell like

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Replacement of cast iron ring by

refractory rings in Refractory wall.

1) Change in % of graphite in sealing paste

2) Change in % of graphite in cathode block

3) Change in collector bar composition

4) Change in geometry of collector bar

5) Change in thermal properties of side wall lining

Unit witnessed drastic change in Cathode Voltage Drop (CVD) reduction from 349

mV to 285 mV in early stage which resulted in gain of 204.8 kWh/MT.

2. Reduction of heavy furnace oil consumption in anode baking

furnace.

With aging of baking furnaces,

different type of defects like flue

wall bending, crack, uneven

degassing gaps etc. are evolved.

These problems in furnaces

severely increase the false cold air

ingress from atmosphere. As a

result, the fuel utilization is

affected significantly. The following

improvement measures were

undertaken to reduce the fuel consumption:

Improvement initiatives:

• Preheating Curve optimization.

• Heating Curve optimization.

• Heat Loss & Cold Air Ingress

Prevention.

• Effective Sealing of peep hole covers.

• Double Polythene Covering.

• Reduction in nozzle jamming.

• Peep hole cover design modification.

• Refractory castable ring implementation.

• Scheduling the maintenance of thermocouple sheet.

Fuel saving: 3,168 kL/annum

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3. Other EnCon Initiatives in 2013-14

• Current efficiency improvement in aluminium smelting pots from 93.2 to 93.7%.

• Reduction in average pot voltage from 4.303 to 4.267 V by taking different

improvement initiatives(riser drop reduction, CVD reduction by modifying cell

relining design, clamp drop reduction)

• Reactor Venturi modification and air chamber plug modification and cleaning of

all air slide air chamber.

• BTAP unloading time reduction resulting in power consumption reduction of de-

dusting fan and also LP compressor running hour.

• Automatic switching of lighting through PLC.

• Installation of solar energy operated street light in parking area

• Installation of energy efficient motor for “Hopper Blower”.

• Modification of Lighting Scheme for 6.6 kV Distribution Room - 2.

• RPH pump energy consumption optimization.

• Replacement of MH lamps with induction lamps

• Interconnection of spray and main jockey pump header.

• Number of HP compressor running optimization done (5.6 to 5.01) by pressure

control and process optimization.

• Interlock between ungrouping and grouping scrapper conveyor and reduction of

idle run time.

• Overhauling of Cooling towers and VFD installation in CT fan motor and pumps

ENVIRONMENT INITIATIVES

SSL has adopted best in class technology for environment management system for

monitoring and control. As a responsible corporate citizen SSL has adopted eight

policies for sustainable development. The 8 signed policies are: HSE Policy, Water

Management Policy, Energy and Carbon Policy, Biodiversity Policy, Human Rights

Policy, Social Policy, Supply and Contractor Management Policy, HIV/ AIDS Policy,

Stake holder engagement Policy.

SAFETY

Unit follows the following best practices in safety.

Best Practices of Safety

• Visitor Management at Workplace.

• Senior Management safety walks down and audit.

• Yellow and Red Notices for safety and environment violations.

• Entry passes for High Risk Areas.

• Reporting of Unsafe Act and Conditions by each employee in portal.

• On job training and class room training for safety awareness.

• Focus on Behaviour Based Safety - BBS & STOP audit

• Implementation of Change Agents for Safety, Health & Environment CASHe

projects.

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Energy Policy

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Certificate of Merit Aluminium

SESA STERLITE LIMITED

Lanjigarh (Odisha)

Unit Profile

Sesa Sterlite Ltd is one of the world’s largest diversified natural resource companies.

The Alumina Refinery at Lanjigarh is having 1 million tonne per annum production

capacity which includes other associated facilities such as - a 75 MW Captive Co-

Generation Power Plant (CCGPP), 65 kilometer Water Pipeline from Kesinga to the

Plant and 16 kilometer long Railway Corridor connecting the Refinery to nearby

Ambodola Railway Station. The Company is planning to expand the Plant from 1

million to 6 million TPA. This is the only Alumina Refinery in the Country having

successfully implemented Zero Discharge System and actively working on the Zero

Waste Projects for the first time across the Globe. The final product is smelter grade

calcined alumina which is being dispatched to group companies situated at Balco

and Jharsuguda locations.

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Specific Energy Consumption Toe/Ton

Note: In FY 2012-13 from Dec’12 to Mar’13 and in FY 2013-14 from Apr’13 to

Jul’13, alumina refinery was under shut down due to scarcity of major raw material

(bauxite). Because of this, energy consumption is at higher side in these years

Energy Conservation Achievements

• 1st metal and mining company in the world certified with ISO: 50001:2011 for

Energy Management System.

• Around 78 energy saving projects have been implemented in last three years

generating saving of more than 0.5 GJ/MT of alumina production

• Development and Implementation of Innovative and Breakthrough Energy

Efficiency Improvement Projects

• SCADA based Energy monitoring & Management System (EMS) is implemented.

• First refinery in the world which prepared a roadmap to achieve benchmark

energy consumption which is as follows.

Roadmap to Achieve Benchmark Energy Consumption

0

0

0

0

0

2009-10 2010-11 2011-12 2012-13 2013-14

0.3218 0.3231

0.3246

0.34170.3361

Toe/ton

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Energy Management System Implementation

Management Commitment

Major Energy Conservation Projects

Project No. - 1: Heavy Furnace Oil Consumption reduction in Calcination unit of the

Alumina Refinery.

Description: In energy terms Heavy Furnace Oil (HFO) consumption in calcination

unit constitutes around 30 % of refinery’s overall energy consumption. HFO is used

in calcination process to maintain the temperature in calciner unit up to 1100 °C, at

this temperature the Hydrate Cake (Al2O3.3H2O) loses all the attached water

molecules and Alumina (Al2O3) is formed.

The Hydrate Cake,

which is the

intermediate product

of alumina refinery,

is formed by filtering

the aluminum

hydrate slurry using

horizontal pan filters.

After the filtration

process some surface

moisture (7-9 %)

remains in the

hydrate cake. The

Hydrate cake surface

moisture (2013-14)

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was reduced from 7 % to 5.5 %. The specific HFO consumption (2013-14) in

calcination was reduced to 70.5 kg/T. In addition to that some other benefits were

also realized during the project implementation. The specific energy consumption

got reduced from 34.5 kWh/T to 32.1 kWh/T.

Project No. - 2: Control of Common Heater (Trim Heater) Outlet Temperature in

Auto mode.

Description of the energy conservation measure: Reducing energy loses by reducing

the standard deviation of outlet temperature of Trim Heater by making it to run in

Auto Mode.

Root Cause: When Temperature controller (TIC 0426) tries to control the outlet

temperature (TI 0426), the pressure controller (PIC 0001) operates in other way

creating cyclic fluctuation in Outlet temperature with higher SD.

Solution: If a de-super heater works between the PIT and PCV to reduce the steam

temperature down to 140 °C (Saturation temp.) then it will help to minimize the

pressure fluctuation and also improve the recovery of latent heat

Project No. - 3: Energy Conservation by De-Staging of Boiler feed water pump.

Root Cause: Three nos. of BFPs were in

operation to feed water to 2 nos. of

boilers. Out of three, one of the BFPs

was running in partial load. Pressure

drop across the FRS station was 34 bar.

Approach: Reduced one stage of pump.

Result: Pressure drop across the FRS

reduced to 20 bar.BFP header pressure

reduced to 95 bar. Reduction in power

consumption by 100 kW.

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Project No. – 4: Modification of motor pulley size in DBNK PDS transfer pumps.

Description of the energy conservation measure: Reducing energy loses by reducing

pumping capacity and increasing the suction head by maintaining high level.

Root Cause: Pump G24 PU 0025, 26 are designed to handle 1100 m3 flow which is

not required to the

existing conditions,

i.e. having the PDS

tanks at high level

necessitates having

pumping elevation of

only 4 to 5 m.

(including line losses).

Solution: It is quite

adequate to have the

pumping capacity reduced to 600 to 700 m3/hr flow, as unit is maintaining tank

level high (to provide adequate residence time).

Major Projects Related to Safety and Environment

1. Robotic Cleaning of Equipment and pipe lines to minimize human exposure

2. Mobile and static vacuum cleaning systems to minimize dust generation

3. Acoustic and new silencers for noise control

4. Dry Fog system has been provided to control dust emission in bauxite crusher

house & at different transfer points. Water spraying arrangement at bauxite

stock piles has been provided by the unit.

5. Wet scrubber system has been installed to control lime dust in lime handling

area.

6. Dry Fog System to control the dust emission in its crushers and transfer points

and water sprinkler for coal storage yard

7. Dust extraction systems with bag filter are provided to control fugitive emissions

from transfer points, conveyers and silo of alumina handling area

8. Modification of ESP's attached to Coal fired boiler no. 1, 2 & 3 in power plant has

been completed for emission reduction and the PM concentration after

modification is well below the target (100 mg/Nm3)

9. Online monitoring system has been installed for continuous monitoring for exit

concentration of Sulphur di-oxide, Oxides of Nitrogen and Particulate Matter and

also sampling ports have been provided.

10. Water consumption per ton of alumina has been reduced from 18.8m3 to 3.0

m3/Ton of alumina

11. All the waste water generated in the process is being recycled and reused in the

process again.

12. Installation of two STPs, one 360 KLD capacity STP inside the Plant and 150 KLD

capacity in the Staff Colony. Treated water is being used for Horticulture purpose

13. Celebrated World Environmental Day (WED) and Vanamahotshav for

environmental awareness of local villagers

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14. Planted 53459 nos. of sapling planted in 37.2 ha. area for Green Belt

Development

15. Production of cold setting bricks & blocks by utilizing of red mud and fly ash

16. Used fly ash instead of soil to prepare dyke wall

Energy Policy