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Team Hindalco

Welcomes You All

Hindalco Industries Limited, Renukoot

Team Member

1. Mr. Anuj Kumar Verma

2. Mr. Vivek Agrawal

Hindalco Industries Limited, Renukoot 2

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

3

To increase steam economy of

Evaporation Unit II by 0.5 T/T.

Target Project


INDEX

Hindalco Renukoot – Profile & Process introduction

Background of the Project

Concept of the Project

Innovation in the Project

Project Savings & Economics

Challenges faced in implementation

Measurement and Verification

Potential for Horizontal Application

Estimated Life of the Project


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.

Finish Product

Aluminium

Bauxite Alumina

Captive Power

800 MW

Hindalco-Renukoot: Fully integrated Operation

Hindalco Renukoot: Profile


ALUMINA REFINERY

ALUMINA

BAUXITE RED MUD

STORAGE

ASH STORAGE COAL

CAUSTIC FURNACE OIL LIME SPECIALITY CHEMICALS

Po

we

r

WATER

Mud Cake

Ste

am

Co

nd

en

sate

Slurry

Alumina Refinery: Renukoot


“Caring for Energy…………….”

Background of the Project : Energy Consumption Trend


LTD

Unit-II

145 OC

Flash Tank

HTD Unit-I 245 OC

HTD Unit-III

245 OC

HTD Unit-IV 245 OC

Pressu

re

decan

ter

Bauxite

Slurry

HRD

DCW

Mud To washer

Precipita-tion

Calcina-tion

Alumina To smelter

Evaporation-III

Evaporation-I

Evaporation-IV

Evaporation-II

Steam: ~60 TPH

Steam

Steam

FO

Sp

en

t Liq

uor

Strong Liquor

Kelly Press

Spent Liquor

Evaporation-II

“Evaporation is essential step in increasing process liquor concentration & maintaining refinery water balance.”

Make Up Caustic

Total Steam Consumption:

~250 TPH



Renukoot refinery operates on 4 evaporation units.

Evaporation unit-II is the oldest unit among all four with

steam economy ~2.92 T/T while Evap-I & newly installed GEA

Messo Evap-IV runs on ~3.8 T/T.

Steam economy of Evap-II unit has been the perennial

problem and could not be solved by several initiatives taken

in the past.

Liquor flashing unit was installed in May-12 to reduce

evaporation load of existing evaporation units. As a

consequence one out of two bay of Evaporation unit-II

stopped.

Performance of evaporation unit is measured by “Steam Economy”. (Evaporation Rate/Steam)



Evaporation Unit-II operating with two bays i.e “HID” and “Evaporator”

Post liquor flashing Unit installation, “Evaporator” side bay stopped & “HID”

side bay kept in operation.

Performance with this setups.



Several Brainstorming session held with cross functional teams, subject

experts and vendors to improve the Evaporation-II steam economy.

There recommendation was to replace existing unit with latest

technology energy efficient units ( Expensive option).

Fact finding mission was done to explore any stretch in key variables

and team arrived at “Is it possible to add additional effects for

improving heat recovery thus increase in steam economy?”.

To evaluate the viability of the idea and establishing key

engineering/process specification, process simulation model developed

on SYSCAD software & series of simulations carried out.

Various Simulations were carried out to find out no. of optimum effects

along with the HID circuit and it emerged that adding 3 nos. effects is

techno-feasible solution.



Total duration 4 Weeks (complete flow-sheeting & programming).

No. of Simulation Run i.e. 20 ( with different setups/combinations (including Base case).

07/28/13 18:35:36 Project : Production_Upgradation

09Change09FC12 Evap (E:\Ameet SysCAD

Work\SysCAD Projects\Final\Production_Upgradation

09Change09FC12 Evap.spf\)

UMO

Base

Case 01

(with 2

Evap

Effect)

Case 02

(with 3

Evap

Effect)

Case 03

(with 4 Evap

Effect)

HID body in line 3 3 3 3

Evaporation Body In line 0 2 3 4

Total Effect In Line 3 5 6 7

Liquor flow to New FF Tak m3/hr 600 600 600 600

Liquor Feed Flow to Evaporation m3/hr 320 320 320 320

Liquor Feed TemperatureOC 65.98 65.98 65.98 65.98

Liquor Feed Caustic Conc. gpl 246 246 246 246

Liquor Exit Temp From effect Heater to LSHOC 107.3 111.5 112.9 114.0

LSH Htr Exit TemperatureOC 130 130 130 130

Liquor Exit Temp From last effect Flash

chamber (Evaporation Discharge)OC

91.16 86.57 85.04 83.83

Liquor Caustic Conc. From last effect Flash

chamber (Evaporation Discharge)

gpl 266.0 268.3 269.1 269.7

Vacuum on Barometric Condenser mmHg 600 600 600 600

Total vapor load on BC TPH 18.1 17.8 17.6 17.6

Water Required for BC @35 degC m3/hr 482 473 470 471

Water out from BC m3/hr 508 498 488 493

Water out Temp from BC deg C 56 56 56 56

Total Condansate out m3/hr 38.6 38.7 38.7 38.8

Condansate TempOC 61.5 61.5 61.5 61.5

Total Evaporation Rate (Evap+FFTk) TPH 33.2 35.9 36.7 37.4

Toatl steam Consumption TPH 15.7 12.8 11.8 11.0

Steam Economy T/T 2.12 2.81 3.11 3.39

Evaporation-II Phase-II (SYSCAD simulation Results)

Case no. 2 (i.e. 3 nos. Evaporator effects in line with the HID circuit) was selected for modification and implementation in the area



Engineering done to feed input stream from evaporator side instead of earlier arrangement of HID

side. This resulted into:

- Lower pressure drop because of its configuration (~1.1 Kg/cm2)

- Improved heat recovery as bigger Heat transfer area effects (i.e. HID effects) at highest

temperature end.

Innovation in Project

Evaporation Unit # 2 New Scheme ( HID side with Add. Effects in Operation – Phase II


Another major challenge was vacuum system for evaporator effects with this configuration:

- Evaporator side vacuum system can not be taken in line due to conflicting configuration.

- Possibility was worked out to utilized HID side vacuum circuit, technical feasibility

worked out and found suitable & implemented.




Another area requiring engineering modifications was flexibility to revert in old

configuration as during rainy season evaporation load may increase. Facility

implemented with suitable provisions.




Saving Achieved


Saving realization after Project completion

S # Parameters UMO Before After

Total Diff

(After- Before) Dec-12 to Apr-14 May-14 to May-

15

1 Steam Economy t/t 2.95 3.42 0.47

2 Steam Consumption TPH 13.4 10.9 -2.46

3 LSH Temperature OC 130 130 0.06

4 Evaporation Flow m3/hr 315 325 9.65

Power Saving:

Saving Achieved

Hindalco Industries Limited, Renukoot

Pumps Pump Nos./HP Pumps Running (Nos.) Pumps Motor, HP Before After Before After

VT pumps 2 * 60 HP

3 NIL 310 0 2 * 125 HP

Circulation Pump 270 + 250 HP 1 1 270 270 Discharge pump 1 * 40 HP 1 1 40 40

FF Tk. (N) Feed pump 2 * 75 HP 1 1 75 75

HID Feed Pump 2 * 215 HP 1 1 215 215 PLD Pump 2 * 40 HP 1 1 40 40 HID cond. Pump 2 * 10 HP 1 1 10 10 Evap cond. Pump 2 * 20 HP 1 1 20 20 IWR pumps 3 * 180 HP 3 2 540 360

Total 13 9 1520 1030

Power Savings (Before - After), HP (Motor loading assumed 85 %) 417 Power Savings (Before - After), KW 311

18

A. Investment:

S # Item Size

Quantity Cost

(Rs/Unit) Rs (lacs)

Dia Length, mtr 1 Sh-40 Pipe 12" 50 3520 1.76

2 Sh-40 Pipe 10" 40 3433 1.37

3 T/F flange 12" 10 1236 0.12

4 T/F flange 10" 10 1236 0.12

5 Pipe Fabrication and Erection cost 12" 50 325.4 0.16

6 Pipe Fabrication and Erection cost 10" 40 271.8 0.11

7 Miscellaneous 0.10

Total Investment in Rs Lacs 3.75

Total Investment in $ ( 1 $ = 66.30 Rs as on 01-01-2016) $5,659 B. Steam Saving Acquired

1 Steam Saving (Saving for 10

months from May-14 to May-15) 2.46 TPH 890 157.9

Total Saving in MTOE 1467 Total saving in $ ( @ 300 USD / MTOE) $4,40,100

C. Power Saving Acquired

1 Power Saving (For 275 days per year) 310.71 KW 2.89 59.3

Total Saving in MTOE 176.36 Total saving in $ ( @ 300 USD / MTOE) 52908

Total Saving ( B + C ), $ USD/Annum $4,93,008

Pay Back Period (Days) 4.0

Project Economics


Flexibility to revert on earlier configuration.

Cost economics

Challenges Faced in Implementation

Space constraint

Congested Layout of the unit


Potential for Horizontal Application: Yes

Estimated Life of the Project : Recurring

Key Parameters UMO Measurement Formula/Reference Verification

Method

Steam Economy T/T Calculated = Evaporation Rate (TPH) / Steam Consumption (TPH)

Evaporation Rate TPH Calculated = Feed Flow – [ Feed Flow * (Caustic in / Caustic Out)]

Feed Flow M3/hr Flow Element Online Data from PHD Log Sheet: Doc No: DIG-LS-09-R2

FE Calibrated mid of the Month

Caustic IN (Feed) gpl LAB instrument Sample Analysis in the LAB, Frequency: Every 4 hrs

LAB: Potentiometric Titration Calibrated with Std. Solution.

Caustic Out (Discharge)

gpl LAB instrument Sample Analysis in the LAB, Frequency: Every 4 hrs

LAB: Potentiometric Titration Calibrated with Std. Solution.

Steam Consumption

TPH Mass flow meter Online Data from PHD Log Sheet: Doc No: DIG-LS-09-R2

FE Calibrated mid of the Month

Measurement and Verification Arrangement


Thank You

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