P. K.

Pattanaik ,GM(CPP)
and
Ch.P.K.Patro ,DGM (Elect)
NATIONAL ALUMINIUM COMPANY
LIMITED

ESTABLISHED : 7th Jan,1981

 ANGUL CAPTIVE POWER PLANT

CORPORATE
OFFICE SMELTER

DAMANJODI
ALUMINA REFINERY

BAUXITE MINES

VISHAKHAPATNAM.
PORT FACILITY
PRODUCTION CAPACITY
OF NALCO
AFTER EXPANSION

BUXITE 63,00,000 MT
PRODUCTION
ALUMINA 21,00,000 MT

ALUMINIUM 4,60,000 MT

POWER 1200 MW
 POWER DISTRIBUTION

AUX.CONSMP

SMELTER 810 MW
(100 MW)

CONSUMPTION

GRID(45 MW)
AUXILIARY 100 MW
POWER
CONSUMPTION
T & D LOSS 5 MW)
EXPORT TO 45 MW
GRIDCO
SMELTER(810 MW) T& D LOSS 5 MW

TOTAL 960 MW
Compliance to EC Act-2001
 Strong management support
 Energy Conservation Policy
 Appointment of Plant Energy manager
 Energy Conservation Cell
 Return of Energy Consumption data to BEE.
 External and Internal energy Audits.
MAJOR PRACTICES
FOR ENERGY CONSERVATION

1. Conservation of resources.
2. Improved Operational practices.
3. Online monitoring of process parameters and Energy
monitoring
4. Introduction of new and energy efficient technology.
5. Adopting good maintenance practices.
6. Innovative conservation ideas through simple and total
participation.
7. Audits & compliance
1. MEASURES TO
CONSERVE IMPORTANT
RESOURCES
Conservation of Coal
 Coal yard management
 Routine Coal analysis
 Mill fineness control
 Un-burnt loss control
 Mill reject control
OIL SAVING MEASURES
 Improved commissioning practices
 Dry oil gun testing
 Online filtration
 Condition based oil replacement
 Advanced Lube condition monitoring
Water Conservation Measures
 Recycling Ash pond overflow(60000 m3/day)
 Recycling Industrial waste water (5000 m3/day)
 Sewerage Treatment(500 m3/day)
 Dry ash evacuation system
 Rain Water Harvesting
NEW AND ENERGY EFFICIENT TECHNOLOGY
 Energy Efficient Motors
 Variable Frequency Drives
 Energy Efficient Lighting
 Energy efficient Pump coating
 Hollow FRP fan blades
 On line Condenser cleaning systems
 Vapour Absorption Chillers
 Intelligent Power Controllers
LATEST MAINTENANCE PRACTICES
 RLA Studies of Equipments
 Thermography Survey
 Tribology
 Current Signature analysis
 Shock Pulse Measurement
 Ultrasonics
 Vibration Technology
 Helium leak Test
INNOVATIVE CONSERVATION IDEAS & PARTICIPATION

 Suggestion scheme
 Philosophy of 4-Rs:
 Refuse/Reconsider
 Reduce
 Reuse
 Recycle
 Helpline/hotline for prevention of wastage.
ENERGY AUDITING
 Routine checks by Energy cell members /
operation engineers

 Insulation surveys

 Walk down audits by certified

In -house Energy auditors (Quarterly)

 External audit by certified agency

Abstract of EC measures
Sl. Project Implemented Saving per year
No. (coal/ oil/ kwhr)

01 Boiler, APH & Milling system 95,000 T of coal

02 Insulation of Hot spots in Boiler 425 ton of coal

03 Correct amount of PA & SA 15 Lakh KWHr
04 DP across Feed Control Station 29 Lakh KWhr
05 Installation of Condenser Online Cleaning 6750 tons of coal
System (for 3 units)
06 Optimum loading of coal conveyors 5.67 KwH
07 Maintaining optimum compressed air 1.89 Lakh Kwr
pressure
08 Overhauling of inefficient compressor 0.34 Lakh KwH
Abstract of EC measures
Sl.No. Project Implemented Actual saving per
year

01 TREVI test of boiler safety valve floating 30 KL(for 2 units)

02 Group Switching of Lamps of Switch gear 1927200 kwhr

room
03 Dry Gun testing 8units x 365 KL

04 Cooling Tower Fan blades replacement with 2units x 0.64 MU

FRP blades

05 Corocoat coating of CW Pump casing & 2 x 0.524 MU

impeller
 PILOT PROJECT
ON CARBON SEQUESTRATION BY
ALGAE IN CPP NALCO
 CASE STUDY -1

Improved operational practices in

testing of oil guns
Dry Oil Gun Testing
 For ensuring availability of oil guns, regular testing
of oil guns is essential.
 The practice was to take the guns in service twice
in a day only for testing purpose.
 The testing of 12 guns twice daily was consuming
1.5 KL oil.
 The annual consumption on account of testing was
coming to 520KL of furnace oil.
Schematic diagram for LDO
in AB elevation
110 V AC

LONV

220 V DC

LOTV
Schematic diagram of HFO in
AB, CD, & DE Elevations.
HONV 110 V. AC

HOTV 220 V. DC

HORV
Dry Gun Testing continued..

 The testing practice is now to do the testing on

simulation of trip valves only.
 No oil firing is required.
 The testing is complete as it ensures:
Healthiness of Guns.
Healthiness of Ignitors.
Ignitor Advance/Retract healthiness.
Healthiness of Steam and Oil line Valves .
 Thus the availability of Guns at the time of need is
ensured.
Dry oil Gun testing Contd..
 The result of this modification in operational practice
is extremely good.

 There is absolutely no investment.

 The testing frequency is now once in a day.

 The saving is very attractive i,.e 2920 KL of Furnace oil

per Annum.
 CASE STUDY-2

Innovative maintenance practice in Cooling

Water Pumps :
Efficiency enhancement
by pump coating
 improve efficiency & save energy
 property of Reduction in surface
roughness
 Hydrophobic Nature
 Glass Flake Based Polymer
Cooling Water pump
 Rated Capacity : 10000 m3/hr
 Rated power : 920 KW
 Rated head : 25.17 mwc
 Rated speed : 590rpm
 Pump model : JTC 56 NMC
 MAKE : WIPL
Glass filled Polymer coating in CW pumps
 Corrocoat fluiguide coating: the glass flake filled
polyester based resin was applied to the suction
bell, discharge bowl & impeller of Cooling water
pump
Trade name : Corrocoat fluiguide(Kirloskar
Corrocoat)
Coatings of polyglass HA 202
corroglass 232
corroglass 202
The streamlined flow & resultant reduction in
friction helped in enhancing the pump efficiency
 ADVANCED GLASSFLAKE TECHNOLOGY

• The development of in-house Glass flake

technology has allowed for the production of
more uniform and consistent Glass flake
• Glass flake can now be made at sub micron
thickness
GLASS FLAKE TECHNOLOGY - TORTUOUS
PATH
Tortuous path for corrosive ion

Layers of glass flakes

Coating

SUBSTRATE
VIEW OF IMPELLER BEFORE COATING
VIEW OF COATED IMPELLER
Energy saving after coating
Sl Descrip- Before After %
tion coating coat- improve-
ing ment

1 Energy in 832.37 780.60 3.3

KW

2 Flow in 7146 7797 8.4

m3/hr

3 Efficiency 59.61 65.81 10.4

Cost Saving (contd.)
 Old efficiency 59.61%
 New Efficiency : 65.81%
 For average flow of 7500 m3/hr at 20.5mtr head

power required at 59.61% =

702.41Kwhr
power required at 65.81% = 636.24 Kwhr
Effective power saving 66.17 Kw hr
Annual energy saving = 66.17 x 330 x 24
= 524066 Kwhr
 CASE STUDY : 3

Improved operational practices

in Drum level control
 DP ACROSS FRS
 DRUM LEVEL CONTROL IS DONE BY BOILER FEED
PUMP SCOOP AND DP ACROSS FEED REGULATING
STATION
 DP IS MAINT.BETWEEN 8-10 KG/CM2
 HIGHER THE DP BETTER IS THE DRUM LEVEL
CONTROL. BUT SCOOP HAS TO BE MAINTAINED
HIGH.
 HIGHER THE SCOOP , HIGHER THE ENERGY
CONSUMPTION
 HENCE LOWER DP, REDUCED POWER
 DP NOW MAINTAINED AT 3-5 KG/CM2
 POWER SAVING COMPARISION

POWER POWER SAVING ENERGY

DRAWN AT DRAWN AT PER PUMP SAVED PER
DP 10 DP 4 YEAR

3102 KW 3012 KW 90KW 6307200

KWH
 CASE STUDY:4

Adoption of energy efficient technology in

Cooling Towers :
Fan Performance
Q ~P is performance data of fan :
Depends on size, shape and speed of impeller.
Fan performance curve : P & Q at a
particular speed developed by prototype based
on design.
Energy Efficient Axial Flow FRP Fans :
Light Weight Fibred Reinforced Plastics Provide :
 Low moment of Inertia, minimum wear, low
starting torque.
 Composite structure by using glass fibres in
woven mat & rovings and moulding the
impeller with resins.
 High Mechanical strength.
GRP : Glass Reinforced Plastic  Polyester based
Resin.
Heavier
Water absorption is higher.
Less strong compared to FRP.
Less heat dissipation.

Aerofoil design ensures :

High efficiency.
Low noise levels.
Less power consumption.
Long life of gear box, motor & bearing due to light
weight of the fan.
 Energy consumption
With old GRP Blades :
Power in Air flow Hot Outlet WBT.
KW CFM Water cold
temp. Water
temp.
Cell-1 61.27 836700

Cell-2 66.38 1012798

Cell-3 60.25 978530

Cell-4 63.25 977578

39oC 32oC 27.81 0C
Cell-5 62.69 917610

Cell-6 60.68 980434

With Energy Efficient FRP Blades

Power Air flow Hot cold WBT % of

in KW CFM Water Water Energ
temp. temp. y
Savin
g
Cell 1 37.35 1524822 39.04
Cell 2 38.25 1440109 42.37
Cell 3 43.20 1453900 28.30
Cell 4 41.40 1424349 41.5 33 29.55 34.54
Cell 5 41.40 1516942 33.96
Cell 6 42.75 1461780 29.55
Energy & Financial savings
Considering average 30% savings over 60KW
load, the energy saving per fan :
= 18 kw/hr
Savings for 5 fans/Cooling Tower/year (300days
running/yr)
= 18x24x300x5
= 6,48,000 kw-hr
CASE STUDY-5

UTILISATION OF CBD STEAM

CDM project: CBD UTILIZATION
SYSTEM
 Silica deposition on the blades of the LP turbine results in
decreasing turbine efficiency / performance.
 To maintain Silica content < 0.20 ppm , we normally give a
continuous blow down of the boiler drum water.
 Heat lost due to the blow down water.
 System in one of our units has been installed to recover boiler
blow down and reuse the same.
 The blow down is taken to a Flash Tank where the water is
flashed and heavier particles like Silica get settled at the bottom
of the tank. The clear steam / vapour is collected at the top of
the tank and is taken to the boiler through De-aerator.
SCHEMATIC DIAGRAM OF CBD

BOILER DRUM

STEAM
DEAREATOR

BLOW
DOWN
TANK
WATER TO DRAIN
SAVINGS
DM WATER CONSUMPTION WITH 2.2%
60,000 M3/Year
1. MAKE UP PER UNIT PER YEAR

HEAT VALUE OF STEAM AT 138 Kgt/cm2 &

2. 370.8 Kcal/Kg
334oC

3. COAL SAVED = 60,000 X 370.8/4000 5562 mt/Year

Rs.55.621
4. SAVINGS PER YEAR = 5562 X 1000
Lakh/year

5. COST OF CBD SYSTEM Rs.30.0 LAKH