ENERGY SAVING - ALUMINIUM PLANT CASE STUDY
Indian Aluminium Company, Limited
Taloja – Dist : Raigad- Maharastra
Unit Profile
Taloja plant was conceived in late sixties as part of INDAL’s plans to expand and develop its integrated
activities in Western region, mainly with an idea of catering to the increasing demand of Aluminium
products. INDAL’s Taloja Works is located in Raigad District of Maharashtra State, 45 to 50 Kms. from
Mumbai by road. The Plant with initial investment of Rs.16.6 crores (31% of imported components) was
commissioned in November 1971, having a capacity of 11, 500 tons per year of Aluminium rolling. The
plant was formally inaugurated on 25th November 1972. Present capacity of plant is 3600 Tonnes of
rolling sheet per year.
Energy Consumption
Electrical Energy
The connected electrical load to the unit is 27,192 KW, while the electrical energy consumption is around
48 MWh/year. The major electrical energy consuming units are the 4 no. of the preheating furnaces and
4 no. of annealing furnaces. These units consume around 48% of total consumption. The three rolling
mills together consume about 35% of the total load. The 730 KVA DG set is an emergency energy
source. This is operated only during outages of the MSEB power supply to cater the need of remelting
furnaces & recycling plant.
Thermal Energy
Our remelt and recycling furnaces being operated with Low Sulphur Heavy stock (LSHS) oil. The annual
consumption is around 4400T. The oil-fired burners are for melting Aluminum in the furnaces and
thereafter rolling ingots being cast for further process.
Energy conservation projects identified for implementation in current financial year (2002 – 03)
Sl. No Location Description
1. New Remelt Install VFD for cold water circulation pump
2. Old Remelt Temperature controller
3. Air conditioners Install thermostat controls
4. Cooling tower Cold water pump # 3 - replace with energy efficient motor
.
5. Finishing area Interlock DC motor cooling fans with motor run command
6. Lighting Avoid day time lighting
7. Mill cooling tower Install VFD
8. Hot mill Install correct head pump for sump tank
9. New Remelt Temperature controller for cooling tower
10. Air compressor arrest air leakages
11. Canron Remove two stages of the impeller of mill supply pump
12. Air compressor Compressor # 1 - replace with energy efficient motor
13. Lighting Replace copper ballasts with energy efficient ballasts for 40W
fittings
14. Scalper VFD with high efficiency fan for re-circulation fan
15. Soaking pits Optimise operation of re-circulation air fan
16. Recycling Reduce heat loss during metal transfer & pouring and optimize
temperature.
17. Canron Replace existing fan with energy efficient fan for motor ventilation
18. Davy Remove one stage of the impeller of mill supply pump
19. New Remelt Install capacitor banks to improve the power factor and reduce the voltage
drop
20. Cooling tower Install capacitor banks to improve the power factor and reduce the
voltage drop
21. Canron VFD for filter supply pump
22. Davy High efficiency fan for motor ventilation
23. Recycling Optimise combustion air supply to burners
24. New Remelt Improve combustion efficiency of holder
25. Soaking pits Improve insulation of top cover
26. Roll grinder Replace compressed air with blower air for roll coolant tank
27. LCL Install lower rpm motor for stacker and hot air blowers
Additional plans
· An investment of Rs. 18 mio is already in progress to replace all 11KV oil circuit breakers by
Vacuum circuit breaker and in which energy management system in all feeders is being installed having a
target date of completion by the end of this financial year.
· In Remelts
Ø An investment of Rs.27 mio is planned this year to revamp the existing 30 years old remelting
furnaces.
Ø Establish the melter burners oil nozzle changing frequency to take care the controlled oil flow rate
at melter main burners.
Ø Frequent checking of flue gas composition for efficient combustion of fuel oil and oxygen
percentage.
Ø Periodic cross-checking of LSHS oil for its calorific value.
· Revamping and insulation improvement of one each from preheating & annealing furnaces
· Load management in preheating and annealing furnaces through operational controls and MD (
Maximum Demand)controller.
· Conversion of one existing electrically heated Preheating furnace to gas fired furnace
-.
Source:Bureau of Energy Efficiency,India
Indian Aluminium Company, Limited
Taloja – Dist : Raigad- Maharastra
Unit Profile
Taloja plant was conceived in late sixties as part of INDAL’s plans to expand and develop its integrated
activities in Western region, mainly with an idea of catering to the increasing demand of Aluminium
products. INDAL’s Taloja Works is located in Raigad District of Maharashtra State, 45 to 50 Kms. from
Mumbai by road. The Plant with initial investment of Rs.16.6 crores (31% of imported components) was
commissioned in November 1971, having a capacity of 11, 500 tons per year of Aluminium rolling. The
plant was formally inaugurated on 25th November 1972. Present capacity of plant is 3600 Tonnes of
rolling sheet per year.
Energy Consumption
Electrical Energy
The connected electrical load to the unit is 27,192 KW, while the electrical energy consumption is around
48 MWh/year. The major electrical energy consuming units are the 4 no. of the preheating furnaces and
4 no. of annealing furnaces. These units consume around 48% of total consumption. The three rolling
mills together consume about 35% of the total load. The 730 KVA DG set is an emergency energy
source. This is operated only during outages of the MSEB power supply to cater the need of remelting
furnaces & recycling plant.
Thermal Energy
Our remelt and recycling furnaces being operated with Low Sulphur Heavy stock (LSHS) oil. The annual
consumption is around 4400T. The oil-fired burners are for melting Aluminum in the furnaces and
thereafter rolling ingots being cast for further process.
Energy conservation projects identified for implementation in current financial year (2002 – 03)
Sl. No Location Description
1. New Remelt Install VFD for cold water circulation pump
2. Old Remelt Temperature controller
3. Air conditioners Install thermostat controls
4. Cooling tower Cold water pump # 3 - replace with energy efficient motor
.
5. Finishing area Interlock DC motor cooling fans with motor run command
6. Lighting Avoid day time lighting
7. Mill cooling tower Install VFD
8. Hot mill Install correct head pump for sump tank
9. New Remelt Temperature controller for cooling tower
10. Air compressor arrest air leakages
11. Canron Remove two stages of the impeller of mill supply pump
12. Air compressor Compressor # 1 - replace with energy efficient motor
13. Lighting Replace copper ballasts with energy efficient ballasts for 40W
fittings
14. Scalper VFD with high efficiency fan for re-circulation fan
15. Soaking pits Optimise operation of re-circulation air fan
16. Recycling Reduce heat loss during metal transfer & pouring and optimize
temperature.
17. Canron Replace existing fan with energy efficient fan for motor ventilation
18. Davy Remove one stage of the impeller of mill supply pump
19. New Remelt Install capacitor banks to improve the power factor and reduce the voltage
drop
20. Cooling tower Install capacitor banks to improve the power factor and reduce the
voltage drop
21. Canron VFD for filter supply pump
22. Davy High efficiency fan for motor ventilation
23. Recycling Optimise combustion air supply to burners
24. New Remelt Improve combustion efficiency of holder
25. Soaking pits Improve insulation of top cover
26. Roll grinder Replace compressed air with blower air for roll coolant tank
27. LCL Install lower rpm motor for stacker and hot air blowers
Additional plans
· An investment of Rs. 18 mio is already in progress to replace all 11KV oil circuit breakers by
Vacuum circuit breaker and in which energy management system in all feeders is being installed having a
target date of completion by the end of this financial year.
· In Remelts
Ø An investment of Rs.27 mio is planned this year to revamp the existing 30 years old remelting
furnaces.
Ø Establish the melter burners oil nozzle changing frequency to take care the controlled oil flow rate
at melter main burners.
Ø Frequent checking of flue gas composition for efficient combustion of fuel oil and oxygen
percentage.
Ø Periodic cross-checking of LSHS oil for its calorific value.
· Revamping and insulation improvement of one each from preheating & annealing furnaces
· Load management in preheating and annealing furnaces through operational controls and MD (
Maximum Demand)controller.
· Conversion of one existing electrically heated Preheating furnace to gas fired furnace
-.
Source:Bureau of Energy Efficiency,India
G
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