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Vision : To be a World Class Integrated Aluminium & Power Producer Generating Sustainable Value for All Stakeholders

Care

Respect

Innovation

Excellence Integrity

Trust

Entrepreneurship

CORE VALUES

CII Excellence in

Energy Management Award

Vedanta Limited, Aluminium - BALCO | 1

BALCO OVERVIEW

Bharat Aluminium Company (BALCO) is the 1st PSU in India’s Aluminium sector incorporated in 1965. One of the first disinvestments of the Government of India & it is now a part of Vedanta Limited, with 51% stake

held by Vedanta Limited and 49% held by Government. Balco is based in Chhattisgarh State having Captive Bauxite mines in Mainpat and Kawardha, Captive coal mines in

Chotia, with 2010 MW power generation capacity and 5.7 LTPA Aluminium Smelting capacity at Korba Complex.

Number of units – 4

Capacity of each unit – 135 MW

Make: Harbin

Spec: Single drum, Natural Circulation, Pulverized Fuel fired, Single Reheat, Balance Draft, and Tangentially Corner Fired

Make: Dongfang

Spec: Reheat, Double steam exhaust, two casing condensing steam turbine

Plant Overview (CPP 540MW)


PROCESS FLOW : POWER PLANT

CPP 540 PLANT PROCESS FLOW DIAGRAM

SEC AIR

300°C

FLUE GAS

340°C

CLEAN GAS

BOTTOM ASH

ASH SLURRY

PRIMARY

AIR GAS

TRAFO

220 KV step up

OLTC

Forced Air Cooled

G 135MW

13.8 kv

SWITCH

YARD

SLURRY PIPE LINES

FLY ASH

COAL PILE

290°C

STEAM TURBINE (135MW)(30+1 STAGE) HIP/LP,Double Exhaust,

Double Casing, Condensing Steam Turbine

POWER

SUPERHEAT STEAM

Pressure=13.7Mpa

Temperature=537°C

ASH SLURRY PIT

COALYARD Ф=80000 T

CRUSHER HOUSE

Ф=4*1000 T/H

COAL BUNKERS (4*4 Nos) Ф=496 T

COAL FEEDERS, Ф= 37 t/h

COAL MILLS(BOWL & ROLLER) Ф=75 t/h

BOILER (PF, Corner Fired, single reheat)

Pressure=14.29Mpa;

Temperature=540°C;Flow= 460 T/h

COAL

CONDENSER (-90kpa) Cooling Area=8500 m3

No. of Tubes 13400 No

INDUCED COOLINGTOWER

Range=8.4 Approach=4

CONDENSATE EXTRACTION PUMP (2) Nos. of Stage- 5, O/L Pr. =18.91 Ksc; FLOW=373 m3/h

LP HEATERS, 4 Nos.

DEAERATOR & FST Pr.=0.709Mpa, 140m3

BOILER FEED PUMP(2Nos.) O/L Pr=181.45 Ksc (max) Maximum Flow=560T/H

HP HEATER, 2 Nos

FEED WATER

166.6 Ksc, 245°C

FD FANS(2 Nos), FLOW=342 t/h

AIR PRE HEATER, 2 Nos

PA FANS(2 Nos)

T FLOW=196 t/h

ESP (2*5 Fields) U#2 (1

st 2 field BAG FILTER)

ID FANS(2 Nos), FLOW= 855 t/h

STACK

H=275 mtr.

TO ATMOSPHERE

DEWATERING BIN, 3 Nos

ASH DYKE

AIR FROM ATMOSPHERE

CW PUMP(2 Nos.)

Flow=10800 M3/H

147°C

141°C

169°C

171°C

44°C

COAL

COAL WITH HOT PA

FLY/BOTTOM ASH

COLD AIR SUPERHEATED STEAM

CONDENSATE WATER

HOT AIR

COOLING WATER

MIXING TANK, 2 Nos

FLY ASH

SILO (2 Nos)

GEHO, 2Nos (208m3/hr)

ASH

CONDITIONER

Seal Air Fan


ENERGY OBJECTIVES

EnMS Objective (FY 18)

Reduction in Specific Coal Consumption(SCC) from 720 gms/ kwhr to 707 gms/ kwhr Reduction in Specific Oil Consumption (SOC) from 0.35 ml/ kwh to 0.28 ml/ kwhr Reduction in Auxiliary power consumption (APC) from 10.11% to 9.62%

Reduction in Specific Coal Consumption(SCC) to 690 gms/ kwhr Reduction in Specific Oil Consumption (SOC) to 0.22 ml/ kwhr Reduction in Auxiliary power consumption (APC) to 9.30%

EnMS Vision (FY 21)


S. No Description Certification

1 Quality management system ISO 9001:2008

2 Environment Management System

ISO 14001:2004

3 Occupational Health & Safety Management System

OHSAS 18001:2007

4 Energy Management System ISO 50001:2011

5 Asset Management System ISO 55001:2014

6 International Automotive Task force

TS 16949

ENERGY POLICY & CERTIFICATION


ENERGY CONSERVATION JOURNEY & REVIEW MECHANISM

Energy Excellence Model

Bench-marking

Innovation Awareness Involvement Certification

& Awards

Energy Saving, Cost Reduction, Sustainable Operation

Corporate Sustainability Review

Monthly Management Review by CEO

Monthly Operational Review by Plant Head

Weekly Energy Cell review by Energy Manager

SBU Level review – Daily War Room Turbine Steam Path Audit

Energy Efficient Drives

Ultra High Filtration System

CW Pump Trimming & Coating , Replacement turbine seals

2015

2016

2018

2017


BENCHMARKING

<300 MW

KPI UOM

BALCO CPP 4x135 MW

JSG 9x135 MW

LAPANGA 6x150 MW

KSK WARORA 4x135 MW

JSW TORANGALLU

2x130 MW

NALCO 10x120

MW

2015-16 2016-17

PLF % 74 70 82 67 73 98 64

PAF % 87 93 92 100 85 98 85

APC % 10.7 10.11 9.8 8.2 9.66 8.93 11

Heat Rate

Kcal/ KWh

2686 2593 2450 2370 2400 2493 2790


INNOVATIVE PROJECT 1 - TURBINE HPDE & LPDE CORRECTION

Why: To maintain MS and RH steam parameter at rated value. How: Modification at front pedestal & HP/LP rotor coupling

Front Pedestal

HIP Turbine LP Turbine

1 2 3 & 4 5

1. HIP Front Pedestal (MOP, Bearing -1)

2. 2nd Pedestal (HIP LP Rotor Coupling, 2 no Journal Bearing, 2No Thrust Bearing)

3 &4. 3rd Pedestal (LP Generator Coupling, 3rd Journal, 4th Journal Bearing, Turning Gear)

5. Generator Rare Pedestal (5th Journal Bearing & Excitation System)

Gen

Expansion Increased from 10 mm to 20mm

Spacer plate width reduced by 2mm

LPDE reduced from 7.5 to 4.5 mm


TURBINE HPDE & LPDE CORRECTION

welded Joint between header and Bearing pedestal

Flexible joint between header and Bearing pedestal

HP Turbine Front Pedestal Modified Lub oil piping

Before After


SAVING- TURBINE HPDE & LPDE CORRECTION

0

1

2

3

4

5

6

7

8

mm

LPDE

2016

2017

Result: During turbine major overhauling, LPT Bottom casing and front bearing pedestal is removed and its contact surface finishing for smooth expansion of casing. Bellow installation in pipe for lube oil inlet & outlet for main oil pump to facilitate the free movement of front pedestal.

500

505

510

515

520

525

530

535

540

545

o C

Main Steam Temperature

2016

2017

450

460

470

480

490

500

510

520

530

540

550o C

Reheat Steam Temperature

2016

2017

Description Savings Unit Temperature Utilisation in MS & RH Cycle

15/60 Deg C

Impact on Specific Coal Consumption

8.609 Gms/KW

hr Direct saving in Coal Consumption

28668 MT / Year

Cost Saving @ 2.74 788.37 Lacs in

INR

0

0.5

1

1.5

2

2.5

3

3.5

mm

HPDE

2016

2017


INNOVATIVE PROJECT 2 - APH PA SECTOR MODIFICATION

Why: To reduce primary air pressure difference across Air Pre Heater. How: By reducing the SA side opening & modification of PA sector plate


INNOVATIVE PROJECT 2 - APH PA SECTOR MODIFICATION

APH Primary Air side Old Sector Plate APH Primary air side new sector plate

Degree of opening for PA section has been increased from 50 deg to 60 deg Degree of opening for SA section has been decreased from 130 deg to 120 deg New main 20 degree sector plate were erected in both Hot & Cold end center sections


SAVING - APH PA MODIFICATION

0

50

100

150

200

250

300

350

400

mm

of H

2O

APH – A PA Differential Pressure

2016

2017

Result:

PA DP across APH reduced to 180 mm H2O from 325 mm H2O after modification

Additional PA fan stopped.

0

50

100

150

200

250

300

350

mm

of H

2O

APH – B PA Differential Pressure

2016

2017

Specific Power Consumption Power Saving Unit

Stoppage of PA fan 6.50 MU/Year

Cost Saving in INR 133.68 Lacs/Year


INNOVATIVE PROJECT 3 - REDUCTION IN RH ATTEMPERATION

Why: To reduce attemperation in hot reheat steam

How: Removal of outer loop of final reheat panel.

RH tube loop removed and made dummy towards header side

0

2

4

6

8

10

12

14

16

April May June

T/H

r

RH Attemperation Spray

2016

2017

Description Savings Unit

Reduction in RH

Attemperation Spray 8 T/Hr

Impact on Specific Coal

Consumption 1.89 Gms/KWhr

Direct saving in Coal

Consumption 6318.03 MT / Year

Cost Saving 173.74 Lacs in INR


Utilization of heat in flue gas: Utilization of waste heat from the flue gas leaving the boiler by installing additional tubes at the bottom bank of economizer, thereby achieving 12o C reduction of flue gas temperature at APH inlet after modification.

Description Savings Unit

Reduction in Exit Flue gas temperature of APH

8 deg C

Impact on Specific Coal Consumption 2.27 Gms / KWhr

Direct saving in Coal Consumption 7581 MT

Cost Saving 208.4 Lacs in INR

Old tubes

New tubes

Old tubes


MAJOR ENERGY CONSERVATION PROJECTS

S.No Title of Project Saving

Lacs / Annum in INR

1 Reduction in O2 % in flue gas (0.29MU) 82

2 Improvement in condenser vacuum(0.66MU) 180

3 Power consumption reduction in Compressors(0.067MU) 18.6

4 Improvement in belt conveyor utilization factor(0.2MU) 54

5 Installation of 10000 18 W LED tube lights in place of 40 W conventional tube lights through EESL scheme (0.91MU) 27.3

6 Installation of Motion Sensors for lighting control in Washrooms / Conference room (0.09MU)

2.7

7 Installation of no's 420 90W LED Street lights in place of 250W HPSV (0.3MU) 9

8 Installation of Led Down-lighter lights in Canteens (0.04MU) 1.2

Total 374.8


Modification done to reduce Turbine LPDE for increasing MS & Reheat Steam temperature.

Addition of extra coil in economiser to reduce exit flue gas temperature

Installation of additional CT cell to reduce cooling water inlet temperature to condenser

Reduction in Specific Coal Consumption (Gms/KWhr)

Reduction in Auxiliary Power Consumption (Kwhr) Installation of VFD in FD & ID

fans. APH modification done to reduce

PA DP and stop one PA fan. Logic provided in DCS to stop

Standby Mill LOP after 30min if mill is not taken in to service.

TRENDS – PERFORMANCE IN PREVIOUS YEARS – SCC & APC


Improvement in availability of boiler & turbine auxiliaries

Deaerator preheating Oil gun Igniter length adjusted to

increase gun reliability. Oil gun nozzle plugging done to

increase operating pressure of oil system and hence impacting atomization

Reduction in Specific Oil Consumption (ml/KWhr)

Reduction in Specific Water Consumption Replacement of drift eliminators Optimization of CT blowdown Zero discharge pit for drainage

water Utilization of ETP Water in AHP &

Fire Fighting water Utilization of storm water Plant Drain line modification to

ensure zero discharge and 100 % utilization of drain water

TRENDS – PERFORMANCE IN PREVIOUS YEARS – SOC & SWC

2.57


Action Plan

Turbine seal replacement Dynamic classifier Operational changes to be discussed and

implemented. Condenser tube bundle replacement Arresting air ingress in boiler Reduction in super heater attemperation

707

701

695

FY 17-18 FY 18-19 FY 19-20

SCC (Gms/Kwh)

FUTURE TARGETS – SPECIFIC COAL CONSUMPTION


Action Plan Reliability improvement of boiler & turbine auxiliaries Oil gun nozzle modifications to be done to minimize oil

consumption during startup Feasibility study to be done for use of plasma ignition Operational changes to be discussed and implemented

Action Plan

Inspection and replacement of all Boiler feed pumps cartridge to be done.

All lighting in open areas to be replace by timer control or based on sensor control.

Reduction in compressed air consumption

FUTURE TARGETS – SOC & APC


EMPLOYEE INVOLVEMENT TOWARDS ENCON

ENERGY MONTH PRIZE

DISTRIBUTION


Reduction in BALCO’ Specific water consumption 2.3 m3/MT (FY16) to 1.4 m3/MT (Lowest ever)(FY17) Balco has won the "FAME Excellence Award 2016" in Environment Protection - Gold Award Balco has been awarded for being the Winner in the LARGE SCALE Manufacturing category [Above 3000

employees] of Safety, Health & Environment Awards 2015-16 from the Confederation of Indian Industry.

ENVIRONMENT MANAGEMENT INITIATIVES

IMS Year No. of NC No. of Observation Open NC Open Observation

CPP 540 15-16 0 7 0 0

CPP 540 16-17 0 4 0 0

Status of EnMS (ISO 50001:2011) Audit Observation

ESP Bag Filter Retrofitting

Design ESP had 5 Fields Ammonia Dosing was in practice to

increase the conductivity of fly ash Average SPM was more than

100mg/Nm3

In ESP, last three fields were replaced with fabric filters

Ammonia dosing stopped in all units

Average SPM is below 25 to 30mg/Nm3


Tangible Benefit : 23.79 Cr of Indian rupees till Mar’2017 Environmental Benefit : Saving of 85384 MT of Coal till Mar’2017. : Reduction in Greenhouse gas emission of 96388 tCO2e.

GHG INVENTORISATION

Actual unit generation at 69% PLF for

FY 16-17 3284

Million

unit

Coal consumption @ SCC of 746 2449864 MT

Coal consumption @ SCC of 720 2364480 MT

Total coal saving 85384 MT

Coal price FY 2016-17 per MT 2787 Rs

Total saving 23.79 Cr Rs

GHG emission

GHG Emission @ SCC of 746

4602747 tCO2e

GHG Emission @ SCC of 720

4506359 tCO2e

Total reduction 96388

tCO2e


ENERGY MONITORING SYSTEM

1. Installation of Online EMS system

2. All relevant energy data is captured from these resources at

regular intervals by PDHR data..

3. Integrated energy monitoring system in place

Pro

cess S

core

Card

PERFORMANCE INDICATORS Unit ON DATE

BP Actual

Gross Generation MU 9.29 12.365

Gross Generation MW 387.10 515.21

PLF % 71.68% 95.41%

Aux.Cons. (MU) 1.21 1.21

Aux Cons. % 13.02% 9.82%

Coal consumption MT 8914 8587

SCC (based on actual GCV) (gms/kwh) 960 694

LDO consumption KL 1.13 0.00

HFO consumption KL 2.26 0.00

Total Oil Consumption KL 3.39 0.00

SOC (ml/kwh) 0.36 0.00

AP

C &

SC

C V

aria

nce

Online EMS System


Use of Drain water in AHP:- By connecting drain line to bottom ash slurry Pit. By this modification, we are able to utilise rain water.

Rainwater harvesting is carried out as part of the Company’s commitment towards environment

100% utilization of ETP discharge water in AHP, Fire fighting and in gardening.

Recycling of plastic waste generated after CT cell fills replacement. Installed 28 KW Grid connected Solar power plant & Planning for

Installation of 5 MW Grid connected Solar power plant. Planning to make Green building in township

ENVIRONMENTAL & RENEWABLE ENERGY PROJECTS

Real Time SPM

data

monitoring &

acquisition

Fire fighting

water line

rerouting from

underground

to overhead

line

Drain water line

connected to Ash

Slurry Pit

Segregation

biodegradable

& Non

biodegradable

waste

Action Plan for Installation of Solar lighting in Area

SNo. Area Start of Project End of Project

Investment Payback

(Years) Status ( In Lakhs

)

1 Comprehensive Building 01.06.2016 31.03.2017

3 7

28kwp

system

installed 2 DM Plant 25

3 Lab building

01.04.2017 30.10.2017

10

7 4 Canteen Plant-2 3

5 HSE office - Plant-1 20

6 Rectifier - Potline-1 01.11.2017 31.03.2018

25 7

7 Rectifier - Potline-2 10

Total 96 7


WASTE MANAGEMENT

Zero Discharge Project: 100% utilization of ETP water for water washing in AHP & boiler area. CT Over flow reduction/ blow down optimisation & maintaining COC above 8.0. Storm water drain line modification to ensure zero discharge and 100 % utilization of drain water.

Ash Utilization:

Ash utilization increased from 30% to 40%

1. Chotia mines backfilling : 10%

2. Ash dyke rising : 20%

3. Road & Brick : 5%

4. Low lying area backfilling : 5%


GREEN SUPPLY CHAIN

Usage of domestic coal instead of imported coal.

Increased capacity of coal trucks from 20 Ton to 32 Ton.

Unloading of coal through Truck Tippler project.

Use of aluminium boxes in place of wooden boxes by local vendors

Door delivery of stores material.

Usage of energy efficient SKF bearings

FY 15 – 183700 FY 16 – 102500 FY 17 – 87000

Additional measures for energy reduction :-

Distribution of 5000nos Energy booklet in all schools of BALCO for increasing awareness towards energy conservation.

Implemented Cardinal rules for energy savings best operational practices.

Distribution of total- 48717 Nos energy efficient light fittings and fans through Ujjala Scheme of EESL:- (May-16-June-16) & (Jan-17 –Apr-17)

PLANTATION DRIVE


ENERGY SAVINGS FROM EMPLOYEE & STAKEHOLDER INVOLVEMENT

Details Unit 2014-15 2015-16 2016-17

FIP Projects No. 5 3 6

QCs / Kaizen Projects No. 25 15 18

Energy Savings Kwh 7664358 4375000 26892304

Benefits due to energy savings Rs. lacs 229 131 806

Vendus Meet to promote Energy Conservation

and Sustainability among Vendors

LED distribution Counter (EESL) at township


AWARDS AND ACCOLADES


Title of Project Name of the

Vendor

Per unit energy consumed % Improvement

Before Project After Project

Distribution of energy efficient light fittings and fans through Ujjala & Pawan Scheme in Balco township

EESL 72000 Kwh/day 68000 Kwh/day 5.55%

IMPLEMENTATION OF BEST PRACTICES

Implementation of Idea generation portal & !DEA@BALCO APP for generation of idea for All Balco & Contract employees. Idea generated - 826 Idea implemented - 105 Idea under implementation - 206

Initiatives taken by supplier has resulted in energy consumption reduction

Thank You!

Bharat Aluminium Company Limited

Korba, Chhattisgarh

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Care Respect CII Excellence in - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/Power/BALC… · Vision : To be a World Class Integrated Aluminium & Power