Primary aluminium production follows two major processes first is refining of bauxite to alumina and second is smelting of alumina to aluminium. Smelting is an energy intensive process and consumes electrical energy, accounting for about 85%–90% of the electrical energy consumption.Aluminium sector has been categorized on the basis of their process in to four subsector i.e. Refinery, Smelter, Integrated and Cold sheet mill.

The total average reported energy consumption of these designated consumers is about 7.71 million ton of oil equivalent/year in the baseline period (2007-10).

By the end of the first PAT cycle, the energy savings of 0.456 million ton of oil equivalent /year is expected to be achieved, which is around 7% of total national energy saving targets assessed under PAT.

This section contains best practices in energy efficiency adopted by leading aluminium industries in 2012-2016. The case studies from KEP workshops, roundtables and National Energy Conservation Awards, 2012,2013 are presented here.

Resource Name: Spent Pot Lining- Alternative Fuel & Raw Material for Cement Industry by NALCO

Abstract: The presentation by NALCO described the annual quantity of SPL available at NALCO for disposal, which is approx. 4500-5000 TPA. The major issues involved in the use of SPL are explained in the presentation, which includes, non-availability of a cost effective  technology for SPL treatment and disposal, regulations involved  for transportation  of the material to outside parties and storage of this material at their sites, reservations  shown by other industries for  acceptance  of this hazardous  and heterogeneous material and very high  cost  for  co-processing   in  cement industries.

Published by: Presentation by NALCO at Policy Roundtable on  “Promoting use of Spent Pot Liners in Cement Co-processing”

Resource: Presentation by NALCO

Resource Name: Spent Pot Lining- Alternative Fuel & Raw Material for Cement Industry by Team Vedanta Group (BALCO, Lanjigarh and Jharsuguda)

Abstract: The presentation by Team Vedanta shared a brief about SPL, its availability in Vedanta plants and its various characteristics were shared by Team Vedanta. Gross Calorific Value (GCV) of first cut material varies from 3200 to 4500 kcal/kg (without wash) and Hardgrov Grindability Index (HGI) is 39 units. Cement Industries like Rishi Cement, UltraTech Cement and Subhra Chemical have tried Vedanta’s SPL for use in their plants. Team also shared some global experience on usage of SPL, such as in ALBA (Aluminium Bahrainm, one of the largest industrial companies in the Middle East), ALCOA (Aluminum Company of America), EGA (Emirates Global Aluminium) and RUSAL (World’s second largest aluminium company, with headquarter at Moscow).

Published by: Presentation by Vedanta Group (BALCO, Lanjigarh and Jharsuguda) at Policy Roundtable on  “Promoting use of Spent Pot Liners in Cement Co-processing”

Resource: Presentation by Team Vedanta

Resource Name: Spent Pot Lining- Alternative Fuel & Raw Material for Cement Industry by Hindalco Group

Abstract: The presentation by HINDALCO Group gives details on the average SPL generation and availability in Hindalco plants. Presently SPL availability from three plants of Hindalco (Hirakud, Aditya and Mahan) in FY 2016 will be about 12,000 Ton per annum (TPA) which may marginally increase to 13,800 TPA by 2020.  SPL generation of 6021 TPA in Renukoot plant is being reprocessed in cryolite recovery plant to recover Cryolite for its recycling in smelter pots.

Published by: Presented by  Akhileshwar Nath Upadhyay, Manager Sustainability and Environment, Hindalco Group at Policy Roundtable on  “Promoting use of Spent Pot Liners in Cement Co-processing”

Resource: Presentation by Hindalco Group

Resource Name: Spent Pot Lining- Alternative Fuel & Raw Material for Cement Industry by Vedanta Limited

Abstract: The presentation by Vedanta Group shared the challenges faced by the both Aluminium and Cement Sector in the area of raw material and energy availability, disposal of waste and stringent environmental norms.  The availability of SPL in Vedanta Group is expected to increase from a present level of 21,000 TPA to 52,000 TPA in future. There are two types of SPL treatment; Disposal and Recycling techniques; Recycling is an attractive and proven option and can be best if its use in Cement Industry.

Published by: Presented by  Dr. Mukesh Kumar, President, Head Group Technology, Vedanta Limited at Policy Roundtable on  “Promoting use of Spent Pot Liners in Cement Co-processing”

Resource: Presentation by Vedanta Limited

Resource Name: Best Practices Presentation by Sesa Sterlite Limited, Lanjigarh

Abstract: A case study on minimization of coal mill rejection by modifying the mill liners air port ring assembly. Use of fish bone problem solving approach.

Published by: Presented by Sh. S.K. Behera, Sh. U.K. Pathy in Sector Level Workshop for Aluminium Sector

Resource: Best Practices Presentation by SSL, Lanjigarh

Resource Name: Implementation of Energy Management System  ISO 50001 by NALCO, Angul

Abstract: A case study on Implementation of Energy management System ISO 50001 in NALCO, Angul. The resource elaborated the experience of NALCO in implementation of ISO 50001. It also covers the scope of EnMS in different plant sections, the energy baseline, PDCA cycle, energy planning and energy performance indicators

Published by: Presented by Sh. S.K. Jena, NALCO in Sector Level Workshop for Aluminium Sector

Resource: Implementation of ISO 50001 by NALCO, Angul

Resource Name: Presentation on Plant Data to Smart Data by Siemens

Abstract: A presentation by Siemens on  data integration in the plant,  conversion to smart data, data analytics, technology based and data driven services to improve reliability and availability. Condition monitoring of loads and energy analytics, better process control.

Published by: Presented by M/S. Siemens, Mumbai in Sector Level Workshop for Aluminium Sector

Resource: Presentation on Plant Data to Smart Data by Siemens

Resource Name: Presentation by Atlas Copco

Abstract: A presentation by Atlas Copco on energy efficiency improvements in compressed air systems,  innovative systems and design in compressed air systems

Published by: Presented by Atlas Copco in Sector Level Workshop for Aluminium Sector

Resource: Presentation on energy efficiency in compressors by Atlas Copco

Resource Name: Small Group Activity on Reduction of PA and ID fan loading by SSL, Power Plant, Jharsuguda

Abstract: A presentation by Sesa Sterlite Limited on energy efficiency improvements electrical loads, reduction in PA and ID fans loading, factors leading to higher loading of the electrical drives.

Published by: Presented by Sesa Sterlite in Sector Level Workshop for Aluminium Sector

Resource: SGA on Reduction of PA and ID fan loading by SSL, Power Plant, Jharsuguda 

Resource Name: Small Group Activity on Optimization of Air Compressor, SSL, Power Plant, Jharsuguda

Abstract: A presentation by Sesa Sterlite Limited on energy efficiency improvements electrical loads, reduction in PA and ID fans loading, factors leading to higher loading of the electrical drives.

Published by: Presented by Sesa Sterlite in Sector Level Workshop for Aluminium Sector

Resource: Small Group Activity on Optimization of Air Compressor, SSL, Power Plant, Jharsuguda

Resource Name: Best Practice Presentation by Sesa Sterlite Limited, Power Plant, Jarsuguda

Abstract: A presentation by Sesa Sterlite Limited, on learnings from ISO 50001 implementation, ENCON efforts undertaken, Process improvements, technology improvements, hydraullic roller technology.

Published by: Presented by Sesa Sterlite, Power Plant in Sector Level Workshop for Aluminium Sector

Resource: Best Practice Presentation by Sesa Sterlite, Power plant, Jharsuguda 

Resource Name: Best Practice Presentation by BALCO, Korba

Abstract: A presentation by BALCO, Korba on Specific Energy Consumption reduction drive for Pot room, reduction in auxiliary power consumption. Erosion of ID fan blades.

Published by: Presented by BALCO, Korba, in Sector Level Workshop for Aluminium Sector

Resource: Best Practice Presentation by BALCO, Korba

Resource Name: Best Practice Presentation by HINDALCO, Renukoot

Abstract: A presentation by HINDALCO, Korba on Energy Management Systems implementation, EnMS – Bottom -up and Top- down approach and use of Thermogrphy.

Published by: Presented by HINDALCO, Renukoot, in Sector Level Workshop for Aluminium Sector

Resource: Best Practice Presentation by HINDALCO, Renukoot

Resource Name: Best Practice Presentation by NALCO, Damanjodi

Abstract: A presentation by NALCO, Damanjodi on Energy Management Systems , salient features of resource use in the plant. Ash slurry pumping and replacement with a new pump.

Published by: Presented by NALCO, Damanjodi, in Sector Level Workshop for Aluminium Sector

Resource: Best Practice Presentation by NALCO, Damanjodi

Resource Name: Best Practices Presentation by Sesa Sterlite Limited, Smelter Unit Jhasuguda

Abstract: A presentation by NALCO, Damanjodi on Energy Management Systems , salient features of resource use in the plant. Ash slurry pumping and replacement with a new pump.

Published by: Presented by SSl, Smelter Unit, Jharsuguda, in Sector Level Workshop for Aluminium Sector

Resource: Best Practice Presentation by Sesa Sterlite Limited, Jharsuguda

Resource Name: Energy Efficiency and Operating Technologies in Alumina Refining- Mr. M. Chaddha, JNARDDC

Abstract: A presentation on Energy Efficiency and Operating Technologies in Alumina refining. ENCON projects completed by SSl, Jharsuguda, efficiency improvements in Pumps, cathode modification, pre heating curve and minimizing the radiation losses.

Published by: Presented on Energy Efficiency and operating technologies in Alumina refininh, Smelter Unit, Jharsuguda, in Sector Level Workshop for Aluminium Sector

Resource: Energy Efficiency and Operating Technologies in Alumina Refining- Mr. M. Chaddha, JNARDDC

Resource Name: Futuristic Energy Efficient Technologies for Aluminium Sector- Dr. Anupam Agnihotri, JNARDDC

Abstract: A presentation on Futuristic Energy Efficient Technologies in Alumina refining. This resource covers analysis of energy required for calcination, tube digestion with autoclave , use of plate heat exchangers and interstage coolers

Published by: Presented on Futuristic Energy Efficient Technologies in Alumina refining, Smelter Unit, Jharsuguda, in Sector Level Workshop for Aluminium Sector

Resource: Futuristic Energy Efficient Technologies for Aluminium Sector- Dr. Anupam Agnihotri, JNARDDC

Resource Name: A Case Study on Pot Cell Design to Save DC Energy, Sesa Sterlite Limited 

Abstract: A case study on pot cell design for saving DC energy. Highlights problems related to voltage drop , high energy cosumption during start up, abnormal cell operation, anode voltage drop, abnormal bath chemistry, high voltage drop at bus bar joints, long duration preheating of cathode surface. The resource also contains a detailed root cause analysis for the above listed problem areas and the possible solutions. The associated savings in energy, cost and improvement in product quality are also included.

Published by: Presented by Sh. Pratap Singh, Sh. Harish Gangisetti in KEP launch workshop

Resource:Best practice case study-IIP_Sesa Sterlite-KEP-01-03

Resource Name: Energy Efficiency Activities through Small Groups

Abstract: This resource presents energy efficiency activities carried out at HINDALCO through Small Groups, it has presented the methodology adopted by the small groups to identify problem areas and development of a solution in a planned manner in assistance from the research, development and design wings of the industry. A case of optimization of pumping power and an innovative solution to stop the use of compressed air in anode boulder breaking are detailed out with the help of this resource

Published by: Presented by Sh. Vivek Agrawal, Sh. Mr. Anuj Verma and Mr. Vivek Kumar in KEP launch workshop

Resource:  Best practice case study-IIP_Hindalco_KEP01-02