Summary for Sambalpur Cluster

Annualized Saving Savings in FY 20

S No Unit No of Initiatives
( Rs. In Crs ) ( Rs. In Crs )

1 Hirakud 34 138.88 71.60

(P&S)

2 Aditya 9 19.21 15

3 FRP 20 17.24 8.62

Total 63 175.33 95.22

 Cost Reduction Initiatives by Hirak
Annualized Saving
Sl No Unit Initiatives ( Rs. In Crs )

1 Smelter Reduction in Contract Manpower 3.01

2 Smelter Reduction of Vehicle inside the plants 1.52

Reduction in welfare ( 2 shift buses, electricity

3 Smelter 1.00
subsidy & travelling ) cost & medical expenses.

4 Smelter Reduction in Security manpower. 0.68

5 Smelter Reduction of Alf3 from 22 kg/Mt to 18 kg/Mt 5.67

Reduction in Aux. Energy from 369 Kwh/Mt to

6 Smelter 340 Kwh/Mt 1.98

7 Smelter Reduction in FTP. Energy from 377 Kwh/Mt to 2.53

340 Kwh/Mt

8 Smelter Redution in SSRI inventory from 1800 Mt to 300 18.75

Mt

9 Smelter Cash generation by selling of Scrap, Dross and 6.00

retired assets.

Reduction in DC Energy from 14562 to 14300

10 Smelter kWh/Mt of Al 18.45

Reduction in DC Energy from 14300 to 14100

11 Smelter kWh/Mt of Al 14.08

Reduction in DC Energy in 235 kA from 13918 to

12 Smelter 8.31
13800 kWh/Mt of Al

13 Smelter Reduction in DC Energy in 235 kA from 13800 to 14.08

13600 kWh/Mt of Al

Reduction in net Carbon consumption from

14 Smelter 4.66
0.442mt/mt to 0.435mt/mt
 Reduction in net Carbon consumption from
15 Smelter 3.33
0.435mt/mt to 0.430mt/mt

16 Smelter Saving in Rodding plant with different initiatives 1.00

17 Smelter Saving in Cast house R&M 1.00

18 Smelter Reduction in service cost 1.00

Replacing ID fans fluid couplings with VFDs in 6

19 Power 1.41
nos of ID fans of Unit-2 Boilers (Boiler-3,4 & 5)

20 Power Replacing ID fan fluid coupling with VFD in ID 0.24

fan-12B

Replacement / Stage reduction of 4 nos of

21 Power existing KSB make Boiler Feed Pumps ( Existing 2.44
-12 stages, with 11 stages)

22 Power Commissioning of VAM- 480 TR. 0.58

23 Power Stage reduction in Unit#1 CEP 0.08

Replacing hydraulic coupling in Boiler feed

24 Power pumps with VFDs ( 2 Nos)  1.19

Replacing existing ACW pumps of 1500 m3/ hr

25 Power capacity with low capacity pump of 1000 m3/hr  0.38
capacity in Unit#3 & 5

26 Power TG-2 Major Overhauling. 7.08

 132 kV Power direct connectivity from CPP to
27 Power 4.90
FRP

Reduction in penalty charges due to power

28 Power overdrawal against contract demand of 20MVA, 2.00
( for next 6 months)

29 Power Reduction in Grid Power Exchange by 2 MW 6.03

Discontinuation of ClO2 treatment in cooling

30 Power water, replaced with sodium hypo chloride 1.25
treatment executed in Apr'19.

31 Power Use of PPF ( Petro Polymer Fuel ) as alternate 0.25

fuel in place of LDO. Trial taken in Boiler no.12

32 Power Installation of screen in coal handling plant to 0.66

reduce fines and improve Boiler Efficiency

Addition of ECO-1 Coil in Boiler#12/13 to

33 Power 3.00
enhance efficiency and capacity

34 Power Zero O.T. after 6th LTS of wage roll employees. 1.92

Grand Total 138.88

n Initiatives by Hirakud Power & Smelter
Savings in FY 20
( Rs. In Crs ) Target Status

1.04 Aug-19 116 nos reduced.

2 nos Tractors , 2 Hydra , 1 JCB , 2 Forklift

0.70 Mar-20 already reduced ( total 7 nos).

1.00 Mar-20 Ongoing

0.41 Mar-20 20nos manpower alredy reduced.

2.36 Oct-19 Ongoing

0.66 Nov-19 Ongoing

0.84 Nov-19 Ongoing

18.75 Mar-20 Ongoing

6.00 Mar-20 Ongoing

6.15 Nov-19 Ongoing

7.04 Mar-20 Ongoing

2.77 Nov-19 Ongoing

7.04 Mar-20 Ongoing

3.46 Oct-19 Ongoing

1.66 Mar-20 Ongoing

1.00 Mar-20 Ongoing

1.00 Mar-20 Ongoing

1.00 Mar-20 Ongoing

0.47 Nov'19 Ongoing

0.08 Nov'19 Ongoing

0.61 Dec'19 Ongoing

0.29 Sept'19 Ongoing

0.03 Oct’19 Ongoing

- Jun’20 Ongoing

0.06 Jan’20 Ongoing

1.77 Nov-Dec’19 Ongoing

 2.45 Sep'19 Ongoing

0.17 Mar'20 Ongoing

0.5 Mar'20 Ongoing

1.25 - Ongoing

0.02 Mar’20 Ongoing

0.06 Ongoing
Mar'20
- Ongoing
Mar'21

0.96 Sept’19 Ongoing

71.60
er
Remarks

106 ( Eng/Cast house-40 , Rodding-20 , Civil-

40 , Potroom -6 ) reduction to be done by
Mar'20.

2 Hydra , 1 MEWP, 1 Metal Carrying Vehicle

yet to be stopped.

30nos manpower to be reduced.

Cash generation by Rs.18.75 Crs.

Furnance -C , 10 Pots , Forklifts & MS Scrap ,

Fluid Coupling, Caster Chiller Plant, 3 nos
Cranes , Old Rail Track , 5
receiprocating compressors, 5 Pot Shell , 1
Dozzer & Idle Assets.
VFDs will be implemented in Boiler-3,4 & 5
after completion of Boiler-10 OH jobs i.e. by
Sept, Oct & Nov'19 respectively, VFDs will be
implemented in Blr-3,4 & 5 during statutory
OH

VFDs will be implemented in Boiler-12 ID Fan-

12B during opportunity shutdown of boiler-
12

4 nos of Inefficient pumps will be replaced by

15th Sept, 5th Oct, 30th Nov & 20th Dec
respectively in phased manner.

Phase-1 and Phase-2 comprising of 260 TR &

70 TR completed. Final phase erection has
started and will be completed by 30 th Sep of
2019.(140 KWH achieved 45 KWH to be
achieved).

Already PO placed. CP raised for VFD.

Techno-commercial offer received from M/s

Yantra Harvest. Expected saving of 85 KW.
Discussion started again with OEMs.

Offers already received. Technical Evaluation

review done. TER Submitted on 8 th Aug.

OH Planned during Nov’19 – Dec’19

(a) Saving of Transmission loss @ 3.6 %
against FRP scheduling.
(b) Elimination of Under injection charges.
(c) Elimination of losses due to FRP Over
drawl against CPP energy.
(d) Merger of 20 MVA + 20 MVA Contract
demand to meet smelter power during
exigencies.

Team from Renusagar, Mahan & Dahej also

visited our CPP for replication.

Discussion with OEM is under progress.

Technical details received from two vendors.
Review is under progress

Capex have been approved,Commercial

negotiation Is under progress

Approval received from PESO Nagpur.

EC amendment under progress along with
Coal Gasification.
 Cost Reduction Initiave
Sl No Function Initiatives

1 Smelter POTROOM - Use of LBD AlF3 in 270 pots (earlier 180 pots)

2 Smelter POTROOM - Low Specific AlF3 Consumption

3 Smelter POTROOM - Specific AC Energy Reduction (by 20kWh/t)

4 Smelter SMELTER - Specific Auxiliary Energy Reduction (by 12 kWh/t)

Change in Materials of Change ( Beaters , seals) and improvement of maintatinence
5 Smelter practice

6 CPP Coal Rake Demurrage reduction tending towards NIL

Optimizing the spares and services cost by change of sourcing or undertaking the
7 CPP
acitivity in-house

8 CHP COAL HANDLING PLANT - Alternative vendor in place of Thyssen Krupp & BEML and
reduction in belt cost
On optimizing the various activities and rationalising the costs we expect the
9 Common reduction

Total ( in Rs Cr.)
uction Initiaves at Aditya Aluminium
Savings (till Projected
Annualized
now) in FY 20 Savings in FY Target date
Saving(Rs in Cr.)
(Rs in Cr.) 20 (Rs in Cr.)

31-Mar-20
3.67 0.00 3.67
31-Mar-20
3.28 0.82 2.46

31-Mar-20
2.91 0.44 2.47
31-Mar-20
1.75 0.58 1.16
31-Mar-20
1.67 0.37 1.30
31-Mar-20
2.04 0.40 1.63
31-Mar-20
1.07 0.48 0.59
31-Mar-20
0.30 0.15 0.15
31-Mar-20
2.50 0.96 1.54
19.21 4.21 15.00
um
Remarks

On increasing the usage of LBD ALF 3 to 90 more pots

Reduction of specific consumption by 1kg/T

On copper insertion the specific electricity consumption will go

down by 32 KwH/T as against P&B
 Cost Reduction Initiatives @ Hirakud FRP
Annualized
Sr No Cost Head Description Uom
Saving(Rs in Cr.)

Reliaility Actions - Hyd & Pneumatic Cylinder RnM

1 RnM Nos 0.05
Cost
2 HRM OperaReduction in filter paper consumption Nos 0.09
3 RnM Power Wiring AMC & other AMC in Electrical LS 0.10

4 CRM/FL OpReduction in consumption of Exxol D-40 KG 0.12

5 Operation AMC OnM contract of ETP & STP LS 0.12

Reliability Actions - Motor Rewinding & Repairing
6 RnM Nos 0.15
Cost Reduction

7 CRM OperaCRM – Rolling Oil Optimisation ( Reuse & Reprocess ) Liters 0.19

Indigenous strap has been developed in place of

8 Packing Mtrs 0.19
Export Finland supplied straps for coil packing line

9 Packing 44GSM Interleaving paper is being used now in place KG 0.19

of 52GSM for CTL sheet inter-leaving
Reliability Actions -Heater & Heater Drives Failure
10 RnM LS 0.20
Ellimination

11 RnM Reliability Actions - Soaking PIT RC Fan Failure LS 0.25

Ellimination
12 Packing Modification of skid and pallets pcs 0.26
Machine shop – Leveller roll , Cutter grinding &
13 FL Pcs 0.36
Machining
CRM & HM Belt wrapper - Belt consumption
14 HRM/CRM O Nos 0.36
optimisation

15 RnM Reliability Actions - Bearing Consumption Reduction Nos 0.40

16 HRM OperaHoughton Oil Consumption optimisation Liters 0.60

Reliability Actions - Oil & Grease Consumption
17 RnM Reduction Ltr / Kg 0.95

Effeciency Improvement - Reduction in cost due to

18 Power CosKwh/T improvement from 1097 to 1010 Kwh/T 3.78

Effeciency Improvement - Reduction in cost due to

19 Recovery % 2.77
Recovery improvement from 65% to 67%
Direct Connectivity at 132 KV of FRP with CPP for
20 Power CosPower Reliability & Cost Reduction LS 6.10

Total 17.24
@ Hirakud FRP
Timelines (Target date
Impact
Responsibility for commencement of
Rs./t benefits)

5 Sandip Choudhary Complete

10 Amit Arora Ongoing

11 Anup Das Sep-19
Sumit Sarkar/Yasir
13 Ongoing
Sheikh
13 Ritesh Prasad Sep-19

16 Anup Das Complete

21 Sumit Sarkar Ongoing

21 Yasir Sheikh October '19

21 Yasir Sheikh Ongoing

22 Anup Das Completed

27 Pavan Singh Mar-20

29 Yasir Sheikh Ongoing

39 Sandip Choudhary December '19

Amit Arora/Sumit
39 Ongoing
Sarkar

43 Sandip Choudray Complete

65 Amit Arora Ongoing

103 Sandip Choudray Complete

409 Power A3 Ongoing

600 Recovery A3 Ongoing

660 CPP+FRP Team Oct-19

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