First Prize

Aluminium

HINDALCO INDUSTRIES LIMITED

Hirakud Smelter, Hirakud (Orissa)

Unit Profile
HINDALCO industries limited (Hindustan Aluminium Company limited) is the largest manufactures of primary aluminium in India and also one of the largest manufactures in the world. HINDALCO is vertically integrated through every stage of the industry including bauxite mining, alumina refining, alumina smelting, semi-fabricating (sheets and foils), product development and captive power generation. HINDALCO Hirakud Smelter is located at Hirakud in Orissa. Hirakud smelter plant pursues production of primary metal, which is based on electrolytic reduction. Expansion and modernization project for increasing the smelting capacity to 146 KTPA presently is completed recently. In the last year Hirakud smelter has successfully converted the HSS (Horizontal Stud Soderberg) Pots to pre-baked pots. The conversion has resulted in high energy saving reducing the DC energy required for smelting process. For meeting the extra power requirement the captive power plant at Hirakud is also expanded from 67.5 MW to 367.5 MW. HINDALCO Hirakud smelter has also taken a coal mine known as Talabira mines near Jharsuguda district of Orissa for meeting the coal demand of its power plant.

Hindalco Industries Limited, Hirakud

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Energy Consumption
With the implementation of various energy conservation projects and the conversion of HSS pot lines to Pre-Baked pots has resulted in substantial energy reduction. There is steady decline of specific energy consumption in the last three years. Below table and graphs shows

DESCRIPTION Annual production Total electrical consumption/annum energy MT

UNIT

2005-06 66347 11020 15006 19108 19.21

2006-07 73008 12480.77 14935 19040.7 17.34

2007-08 99406 16026.35 14195 21668.28 23.8

Lakhs Kwh

Specific energy consumption Kwh/tonne (electrical) Total thermal consumption energy Mkcal

Specific energy consumption Litres/Tonne (fuel)

total specific energy(electrical)

total specific energy(thermal)

15200 15000 14800 14600 kwh/ton14400 14200 14000 13800 13600

2005-06 2006-07 2007-08

25 20 15 Ltr/ton 10 5 0

kwh/ton

Seri

year

2005-06 2006-07 2007-08 year

Total Specific Energy (Electrical)

Total Specific Energy (Thermal)

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SPECIFIC ENERGY REDUCTION

DESCRIPTION DC energy for electrolysis Electrical energy for Rolling ingot 1-20k CG and sow ingot. UNIT Kwh /Ton Kwh/Ton 2005-06 14942 28.62 2006-07 14935 26.34 2007-08 14000 12.75

Energy Conservation Commitment Policy and Set up

HINDALCOs Hirakud Smelter management believes that energy and resource conservation are the two building blocks for Hirakud Smelters sustainable development. The Plant has an Environment and Resource Management (E&RM) cell which primarily focuses on energy conservation. The activities of E&RM cell are reviewed once a month. Measurement, monitoring, managing and implementing new small group activities / in-house projects/new technologies for energy conservation are the functions of this cell. The new proposals for energy conservation projects are discussed in the E&RM cell. Key issues like conducting energy audit through external agencies and financial approval for identified energy conservation projects also constitutes the agenda of the meeting. In an unending endeavor to improve the energy efficiency and capacity utilization, the company has constituted an apex body namely World Class Manufacturing (WCM) Steering Committee which is headed by the Vice President. The World Class Manufacturing is a holistic approach, which incorporates the key features of contemporary initiatives and guides to excel in the field of energy conservation, waste reduction and optimization of resource consumption. Under this concept, excellence and competitiveness go hand in hand which facilitates and encourages all the employees to maintain abnormality free environment and operating conditions. WCM Steering Committee constitutes of 12 WCM sub committees under which there are 48 operating teams across the entire cross section of the plant. As a continued effort towards achieving excellence in the field of energy conservation, a Specific Energy Policy has been formulated for Hirakud Complex, which reflects the commitments of the top management towards conservation of energy, resources and environment. The unit is in fact the first Indian Company in the aluminium sector to have formulated the energy policy. The said policy was also made public by publishing it in one of the national newspaper The Times of India on 23 August 2002. Having formulated the Energy Policy & involving people through SGA approach, the next priority for the Plant is the consolidation of the fundamentals of the Small Group Activities (SGA) at the grass root level which is a challenge being faced by the Hirakud Smelters management. For reaping the advantages and the benefits of a concept or a practice in order to add on to the bottom line of the company, the concepts and the practices adopted need to be streamlined in the form of a well adopted system. Having established and maintained three effective and internationally recognised systems viz Quality Management System ISO 9001, Environment Management System ISO 14001 and Occupational Health and Safety Assessment Series (OHSAS) 18001 at Hirakud Smelter, the company is in process of amalgamating the best practices of all the three systems and thereby evolving a new common system which will cater to the needs of all the three established systems besides the Energy Conservation and Management at Hindalco Hirakud Smelter. The energy management structure at Hindalco Hirakud is given below

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Apex committee Coordinating committee

Energy Monitoring Team

SGA Team

Energy Policy
Energy efficient power generation, aluminium smelting and casting Nurturing energy efficient designs and technology for all future acquisitions, where ever practicable Enhancing utilization of renewable energy resources, wherever feasible Recognizing efforts of our employees and their family members in energy conservation initiatives Going beyond standards, wherever economically viable Yardsticks, which drive us to monitor and improve energy performance through periodic reviews and skill up-gradation of our employees.

Energy Conservation Achievements

Year 1999-2000 2000-2001 2001-2002 2002-2003 2003-2004 2004-2005 2005-2006 2006-2007 2007-2008 No of SGA 21 29 31 35 36 35 30 20 15 Investment (Rs lakhs) 227 152 240 89 806 476 15048 45859.2 21304.37 Savings (Rs lakhs) 169 179 212 197 712 496 888.56 2047 2076.248

18

1. Reduction of DC energy in newly started 85 KA prebake pots by implementation of anode effect termination (AET) technology Before Installation: Before installation of this project the anode effect was killed manually and it was very time taking and also the anode effect duration was high. Before

Energy consumption When HSS Power consumption was 14260Kwh/ton. During prebaked consumption is 14000Kwh/ton. Saving in FY-2007-08 is 425845560kwh.and Rs.258lakh

After installation: In this project they have modified both hard ware and soft ware of the electronic pot controller. After the modification the anode effect killing time has reduced due to auto killing by the controller.

After

2. INSTALLATION OF VVFD FOR COLDWELL MOTOR OF COMPRESSOR COOLING TOWER Situation Before Earlier there was a star delta starter running the motor at full speed and as the pump is of higher size than requirement so the flow and pump of the water line was adjusted with reducing valve opening. Due to reduced valve opening the pump was operating at lower efficiency and friction head losses were more. Situation After After installation of VVFD the valve was made fully open and the pressure and flow is adjusted by varying the motor speed through VVFD. Due to low speed operation the motor is operating with half of the power required before. Total investment-Rs.1.5lakh Saving-Rs.3.45lakh/year

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3. REPLACEMENT OF OLD AIR COMPRESSOR LINES Situation Before The compressor airline was forty years older and there were many leakages in the line, due to this leakage they had to run one more extra compressor for meeting the load demand than the requirement. Also the airlines were laid under the tunnel, so it was very difficult to maintain them. Situation After After changing of the old compressor line with new one laid over head, running of one number of compressor was no more needed, so by this they reduced one number of compressor to run. Total investment-Rs.15lakh Saving- Rs.6.4 lakh (recurring)

4. Demand based switching of air compressors Before installation There are 10 numbers of air compressors for supplying compressed air to the pot line, most of them were running in unload condition for most of the time due to unavailability of sufficient control mechanism, with this they were loosing a lot of no load power consumed by compressors After installation After using this PLC controlled circuit they had saved a lot of power by switching the compressors on the basis of load demand and with complete closed loop control. Installation cost-Rs.60,000 Saving-Rs.90,000/year

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Energy Conservation Plans and Targets

The following energy conservation related projects have already been identified for implementation in the Plant. Progress has already been made in few of these cases as on now.

S.NO 1 2 3 4 5 6

ACTION PLAN Conversion of existing 172pots to pre baked technology Installation of auxiliary energy management system for monitoring of auxiliary energy Installation of VVFD for IR compressor cooling tower Installation of capacitor bank for plant auxiliary sub station Replacement of old rectiformers of rectifier station Installation of VVFD for compressor cooling tower

TARGET MAY-2008 AUG-2009 Aug-2009 Dec-2009 Dec-2010 Dec-2009

Environment and Safety

HINDALCO, Hirakud Smelter subscribes to eco-efficiency. In other words, it entails manufacturing products and providing services in a manner that conserves natural resources, minimizes wastes and ensures pollution control. Because of the above approaches, the unit has been certified by BVQI for ISO 9001:2000 in November 2001. Better environment management at HINDALCO, Hirakud Smelter has enabled the plant to contain its production cost. At Hirakud Smelter an unending quest for environment excellence is demonstrated through implementation of Environment Management System 14001.

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Second Prize

Aluminium

HINDALCO INDUSTRIES LIMITED

Renukoot, Sonbhadra (Uttar Pradesh)

Unit Profile
Hindalco Industries Ltd. (Hindalco), a Flagship Company of the Aditya Birla Group is a Pioneer nonferrous metals powerhouse. Hindalco was incorporated in 1958. Its Renukoot unit was set up in technical collaboration with Kaiser Aluminium and Chemicals corporation, USA and commenced commercial production in 1962.

HINDALCO INDUSTRIES LIMITED

Hindalco, at Renukoot, houses a fully integrated plant, comprising of 3 main plants i.e. Alumina, Smelter & Fabrication Plants. Hindalco produces some Byproducts, which include Gallium Metal, Vanadium Sludge and Aluminium Dross. Each plant employs varying Technology. With integrated facilities, output from various plants is used by next, along with varying raw materials. Company has its own captive power plant at Renusagar (30 Km away from Renukoot) with installed capacity of 741.7 MW and 78 MW of CoGeneration Plant at Renukoot itself. Alumina Plant: - It was commissioned with an initial capacity of 40,000 MTPA, which has now increased, to 700000 MTPA. The plant has been expanded in phases using new technology from time to time for energy efficiency and capacity enhancement. It employs the basic Bayers process and the major raw materials for the plant are Bauxite, Steam, Caustic Soda and Furnace oil. Aluminium Smelter: - It has 11 Pot lines with 2127 Pots installed with annual production capacity of 3,45,000 MT. The Smelter employs the Hall Heroult Electrolysis Process for the extraction of Aluminium from Alumina. Basic raw materials for the smelter are Alumina, Power, Anodes and Aluminium Fluoride. Fabrication Plant (Value Added Products): - The Fabrication Plant at Renukoot comprises of 4 Main Sections Remelt Shop, Cast House, Rolling Mills, Extrusion & Conform which produce Wire Rod, Slabs/Billets, Rolled, Coils and Extruded Products. Hindalco, an ISO 14001, ISO 9001:2000 and OHSAS 18001 Company. Recently these three systems have integrated as IMS (Integrated Management System). Today Hindalco occupies a place of pride in the global aluminium scenario with its most efficient working in all areas of operations. The company has kept pace all along with latest development in aluminium technology and has upgraded its manufacturing facilities. 22

Energy Consumption
Manufacturing of Aluminium is one of the most energy intensive process. The cost of Energy comprises about 41.40 % of the total input costs for producing Aluminium. Hindalco uses 3 types of Energy resources to manufacture Aluminium i.e. Coal, Oil and Electricity. Out of these three, electricity has the highest share (almost 75.23 % of total energy consumption cost). Total cost of energy for last year was Rs. 893.23 Crore, which includes Rs.161.02 Crore for Fuel oil, Rs.672.01 for Electricity, and Rs.60.19 Crore for Coal & purchased steam. Last year company consumed 491836 MT of Coal, 83263.20 KL of Fuel Oil, 61127.15 Lakhs kWh of Electricity and 264329 MT of purchased steam.

Specific Energy (Thermal M KCal/MT)

ALUMINA

ALUMINIUM

3.420 3.400 3.380 3.360 3.340 3.320 3.300 3.280

3.413

0.510 0.500 0.490

3.339 3.336

0.503 0.487

0.480 0.470 0.460 0.450 0.440 0.462

2005-06

2006-07 YEAR

2007-08

2005-06

2006-07 YEAR

2007-08

Billet Casting
0.350 0.300 0.250 0.200 0.150 0.100 0.050 0.000 2005-06 2006-07 YEAR 2007-08 0.320 0.330 0.329

CONDUCTOR REDRAW WIRE

0.350 0.300 0.250 0.200 0.150 0.100 0.050 0.000

0.320

0.290 0.255

2005-06

2006-07 YEAR

2007-08

Specific Energy Consumption (Electrical Trends)

Alum inium 14800 445 440 435 430 425 Alum ina 444 444 432

14762 14735 14740 14710 14680 2005- 2006- 200706 07 08 Year

kWh / MT

kWh / MT

2005-06 2006-07 2007-08 Year

23

Conductor Re - Draw Rod

Billet Casting 329

63.000
kWh / MT

62 59 57

330 325 kWh / MT

328

328

60.000 57.000 54.000

320 315 310 305

2005-06

2006-07 Year

2007-08

300 2005-06 2006-07 Year 2007-08

Energy Conservation Commitment, Policy and Set up

In the present scenario of increasing cost trend towards Energy, Hindalcos well-established Energy Management System is continuously working on Energy conservation. The company has a well-defined Energy Policy to underscore its commitment towards Energy Conservation. To inculcate awareness on the importance of Energy Conservation not only to the employees of the company but also to the society, the following setup is followed. Setting up a dedicated Energy Cell with following agenda to enable the Company to reduce specific energy consumption on continual basis and thus becoming one of the lowest cost producers in the World. 1. To identify potential area for energy saving in consultation with department. 2. To take care of latest technological developments in the field of energy conservation. 3. To suggest measures for better energy efficiency for the implementation in the plants and new projects. 4. To monitor the quantum of energy saved on account of energy conservation initiatives. Arrange Energy awareness program & National Painting Competition for School Children. Arrange Energy Conservation program collaboration with IOC for Housewives on "Cooking Gas Proper Utilization of LPG", "Saving Energy at Home". In-house and outside training program for staff & workmen for "Improved work practices for fuel efficient operation of Furnaces", "Fans" & "Cooling Tower". Company encourages continuous improvement through small group activities under aegis of WCM in areas of Cost reduction, energy efficiency, quality and productivity improvement. In line with Energy Conservation Act -2001 the company has trained 12 engineers to acquire the certificate for Certified Energy Manager/Auditor awarded by BEE. The Company believes in all the modern techniques like TPM, Quality Circle, 5S, TQM, WCM etc. and is striving to become a World class Company in all its operations by creating awareness among employees towards energy conservation as well as resource conservation. The company has well-structured suggestion scheme to encourage employees to give their suggestions for energy conservation and employees are suitably rewarded for viable suggestions. 24

Since the company has strong commitment towards Energy Conservation, the projects, which require investments, are normally approved. Company takes special care to allocate funds for these projects. A Top Down and Bottom Up approach through out the organization is maintained towards Energy Conservation.

25

Energy Monitoring Methodology

A well defined Energy Management Organization Structure

Energy Conservation Achievements

The company has been receiving National Energy Conservation Awards, continuously since 1995. During 2005-2008 company has implemented 177 measures to improve Energy Efficiency (including capacity enhancement) by investing Rs. 29.65 Crore which resulted in a saving of energy worth Rs.40.70 Crore / Year and also increased production.

Year

No. of measures implemented 66 67 44 177

Investment made (Rs. In Lac) 1,868.27 914.88 182.21 2965.36

Savings achieved (Rs. In Lac) 2,636.75 754.40 678.63 4069.78

Energy Cost (Rs. In Lac)

% Saving of Energy Cost

2005-06 2006-07 2007-08 Total

86,730.90 87,325.94 89,322.59 263379.43

3.04 0.86 0.76 1.55

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Major projects implemented during the year 2007-2008

Adopting practice of low stub breaking and Anode setting activities together as well as close monitoring of process parameters to increase the pot's current efficiency. This has reduced the specific Energy consumption by approx 25 Unit/MT. Investment - Nil Money saving = Rs.175.61 Lac/Year

Reduction in surface heat loss from Billet & Cast House Furnaces by changing design of refractory insulation.

Special type (Insulyte-4) Insulation castable

Investment 0.15 Lac Money saving = Rs.8.14 Lac/Year

Furnace Roof

Revamping of 3 Nos. Soaking Pit for improved insulation leading to reduced losses. Investment 102.90 Lac Money saving = Rs.26.81 Lac/Year

Reduction in Sp. Fuel Consumption of Wire Rod by improving combustion efficiency & changing the SOP.

Investment 2.00 Lac Money saving = Rs.50.41 Lac/Year

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To circulate the CEP water through the Gland Steam Condenser to increase the feed water temp thus saving in coal consumption. Investment 2.50 Lac Money saving = Rs.55.01 Lac/Year

31.4MWTG Condensate

B#3 Deaerator

ejector

5.6MWTG gland leak off

Gland steam condenser

Raw water from CT

Interconnection of ACW and CW pump was done and two nos. ACW pumps were stopped during winter season to reduce the auxiliary power consumption. Investment 0.75 Lac Money saving = Rs.19.44 Lac/Year

Turbine d

Boiler & turbine auxiliary

ACW pp

Cooling tower basin

CW pp

In addition of above, following 38 major projects have been implemented during FY 07 08. Saving (Rs. Lakhs) 3.56 3.98 0.92 0.15 1.72 7.37 2.05 2.32 Investment (Rs.Lakhs) 3.00 3.00 0.20 0.15 0.01 1.29 0.65 0.10

SN 1 2 3 4 5 6 7 8

PROJECT DESCRIPTION Evaporation -3 Feed Pumps : Replacement of 150 HP motors by 200 HP motors to avoid duplicate equipment running . Evaporation -3 Homo Liquor Pumps : Replacement of 150 HP motors by 200 HP motors to avoid duplicate equipment running . Installation of float switch to avoid idle running of New ETP Pit sump Pump Installation of energy efficient light in Evapn - 3, Coal tippler & PPT area Control logic has been introduced on DCS to optimize the running of additional condensate pump in precipitation area. Washer over flow pumps speed optimization as per washer over flow tanks level to reduce power consumption. Lime slurry feed pump speed optimization as per additive lime tank level to reduce power Stopping the medium pressure purge water pump used for cooling the gland of Digestion # 1 Blow off pump and bearings of Charge pump & Booster pump of Digestion # 1 & 2 by providing spool.

28

10

11 12 13 14 15 16 17 18 19 20

To stop one small cooling tower by providing the circulating water to all the three bundles of flux cooler of FCB Calciner by increasing the pipe dia from 4" to 6". Development of sweetening control scheme to run sweetening in both Digestion unit # 1 & 2 through single pump instead of dedicated pump. Development of Ball Bill idle run hour software for Ball Bill of Alumina Plant in DCS for close monitoring. This has reduced the specific energy consumption by 3 Units/MT. Primary Feed System Blower stopped through air taken from air lift blower in FTP line-5, 6 & 7. Primary air-slide fan of FTP line-8 stopped by capacity utilization of air lift blower. Filter hopper fluidization fan of FTP of Pot line # 5 & 6 stopped by supplying the air from pot air slide fan. Energy saving by reducing pulley ratio of air lift blowers in Pot line8 FTP. Installation of transparent sheet in roof of Billet casting Area to reduce the ON time of roof lights. Automation of cooling tower fan to control water temperature in the range of 28 to 33 Deg C. Reduction in soaking time of few alloys at Billet Casting Homo furnace to reduce the power consumption. Stopped the running of Sniff Nozzle during non casting time. Making of Sow cake for sell from left out metal of furnace for selected alloys (1050, 1060 &1070) after casting to reduce the scrap generation. Provided the push button and indication lamp for air filter fan on the operator panel of compressor to avoid the idle running. Relocation of switch boards of Stack lights of Pot line # 6 to 11 to avoid the idle ON time. Installation of automatic light sensor in Bath crushing area lights to avoid the manual intervention thus reducing the ON time. Stoppage of Idle running of RAL motor of Pot line # 4 DSS second phase. Replacement of HTM heater with inline oil heater in Slab Casting Furnace. Revamping of Homo Furnace to decrease the heat loss. Interlocking of circulating fan of Solution furnace to avoid the idle running. Replacement of Motor of Caster scrubber unit pumps from 10 HP to 3 HP. Interlocking of LNP coolant pump motor of Davy Cold Mill to avoid the idle running of motor. Feed water heater provided in Co-Generation - 1 to increase the feed water temperature thus saving in coal. Modification in pipe fittings of ash handling line of Boiler # 3 to reduce false air ingress thus reduction in running hour of vacuum pump. Modification in water pipe line of VAM to match the requirement.

5.03

0.20

5.80

0.50

38.28 1.46 1.22 0.31 0.54 0.38 1.31 1.80 0.70 3.36 0.09 0.11 0.03 1.18 1.45 0.48 0.10 0.80 0.09 53.80 2.24 7.05

0.00 0.05 0.20 0.02 0.06 0.56 0.05 0.00 0.00 0 0.02 0.02 0.01 0.25 0.30 40.00 0.00 0.00 0.00 15.60 4.60 0.50

21 22 23 24 25 26 27 28 29 30 31

32

29

33 34 35 36 37

38

To stop the sample cooler pump by providing the connection from raw water line. Provision of on line removal of deposits from 5.6 MW turbine by the use 100 PSI steam to increase the power generation. Relocation of switches for lights of Boiler # 4 by-room to reduce the ON time. Installation of timer in lighting circuit of Co-Generation # 2 condenser area lights to reduce ON time. 3 Nos. air compressors each of 11.2 KW discarded after replacement of Air Blast Circuit Breakers with SF6 Circuit Breakers at Rectifier-II. Development of pump runs hour software for all power intensive pumps of Alumina Plant in DCS for close monitoring. This has reduced the specific energy consumption by 7 Units/MT.

1.30 100.80 0.34 0.05 1.67

0.50 2.00 0.05 0.02 0.00

89.32

0.00

Besides above, a number of energy conservation projects have been completed through Small Group Activities; only some of these have been included above.

Energy Conservation Plans and Targets

Anticipated saving (Rs. Lakhs ) 998.62 Approx. Investment (Rs. Lakhs) 11885.00 Project commencement and completion year 2008-09

Energy Conservation Measures To convert existing high temperature Digestion technology with energy efficient double digestion technology. Construction of drain channels to connect all individual sump pits in filtration area to avoid the individual running of sump pumps to save power. De-linking of Evapn. unit II and III for increasing evaporation rate on account of reduced BPR and stopping one pumping station and power saving. To arrest escapage of HRD waste vapors to heat wash water. To enhance throughput of Ball Mill # 4 from 38 to 48 TPH to reduce the specific power consumption. Efficient way of doing condensate cleaning of precipitation tank air lifts by process generated hot condensate in place of clear water to save steam energy for heating the same. BM # 1 GMD Pump (N) -Motor Rationalization (25 HP-15 HP) BM # 4 GMD Pump (N) -Motor Rationalization (60 HP-40 HP) Piping modification for rerouting Digestion # 3 & 4 dilution lines through Washer # 1 over flow pumps thus removing existing pumping station for unit 3 & 4. 30

2.18

0.75

2008-09

95.89

2.50

2008-09

4 5

3.86 12.00

41.20

2008-09 2008-09

1.04

0.127

2008-09

7 8

0.41 0.69

0.76 1.05

2008-09 2008-09

4.24

0.50

2008-09

Piping modification for catering requirement of 10 sweetening slurry for Digestion unit # 1 & 2 with one pump in place of two separate pumps. Installation of capacitor bank in New Drum Filter 11 MCC, Evp3 MCC, Old PPT MCC, Bauxite Tippler MCC & Ammonia Compressor MCC. Installation of energy efficient light fitting in PPT 12 & Clarification area. Spent Liquor Tank Agitator : Motor H.P 13 rationalization (25 HP motor by 10 HP motor) Installation of VFD in Main Air Slide motors of 14 Plant-2 Reduce energy consumption by increasing 15 anode life from 76 shift to 80 shift. Reduce energy consumption by using bigger 16 size cathode blocks in electrolytic pot. Trial to be taken in 90 Pots in FY 08 - 09 To reduce oil consumption by improving flue 17 design. Reduce steam consumption by using 100% 18 molten pitch in paste plant To stop the Rotary air lock of line-4 DSS 19 hoppers (Phase - 1) by providing a bypass line for discharge of alumina in air slide Energy saving by optimizing the time of fluidization of air slides of Automatic alumina 20 Feeding System of pot rooms by change in the PLC programme. Optimize the running rpm of ventilation fans of 21 Alumina Transfer System between plant # 1 & plant # 2 through V.F.D. Stopping of main air slide fan in FTP of Pot line 20 - 9, 10 & 11 by utilization of additional capacity of filter hopper blower Revamping of Homo furnace electrical control 21 system. Automation to avoid the idle running of cooling 22 fan of Blue star STL DC motor. Modification in hydraulic pipe line Extrusion 23 Press # 5 Platen saw so that one hydraulic power pack could be eliminated. Revamping of one no D C Melting & Holding 24 Furnace of Remelt shop to reduce Radiation Loss. To install Variable Frequency Drive in the FD 25 Fan motor of Co-Generation unit # 1. To install Variable Frequency Drive in the FD 26 Fan motor of Co- Generation unit # 2. To replace Boiler # 2 de-aerator feed pump by 27 Energy efficient feed pump.

3.79

0.10

2008-09

0.77 0.13 1.03 12.29

0.15 0.10 25.0 0.00

2008-09 2008-09 2008-09 2008-09 2008-09 2008-09 2008-09 2008 - 09

7.26

0.4 Lakh / Pot

3.06

0.5

2008 - 09

13.79

0.7

2008 - 09

1.13

0.5

2008 - 09

4.90 0.48 0.29 5.44

1.2 23.0 Nil Nil

2008 - 09 2008-09 2008-09 2008-09

8.18

44.0

2008-09

17.66 9.64 0.46

48.44 21.43 5.50

2008-09 2008-09 2008-09

31

To install RO plant for polishing process 28 condensate coming from Alumina plant for saving of water. Bypassing of A/C cooling tower by providing the 29 water from transformer cooling tower in Pot line # 9, 10 & 11 Switch house Air conditioning units.

16.12

133.00

2008-09

0.80

0.20

2008-09

Environment and Safety

Hindalco is totally committed to sustainable development; hence, building eco-efficiency in all of their operations. The company has a well-drawn out environmental management strategy in place. Environment concerns are textured into all manufacturing processes. In order to ensure that Hindalco comply with all the stipulated environment norms, various state-of-the-art pollution control systems / devices have been installed to prevent and control pollution. With better awareness and appreciation towards ecology and environment, the organization is continually looking for innovative and cost effective solutions to conserve natural resources and reduce wastes. Capacity increase of the existing plant by process innovation, equipment modernizations etc with insignificant increase of pollution load are some of the methodologies that highlight the strategies adopted at Hindalco. Updated fuel-efficient and particulate matter reduction technology (advanced ESPs) has been installed in Calciners and Boilers with Co-generation facilities. Microprocessor based controls and Advance Dry Scrubbing System installed in all Pot Lines to ensure less emission and energy.

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