Automation

Technology for ALUMINIUM

A. Ray
Director,
NALCO
 VISION
To be a Company of
global repute in Aluminium Sector
MISSION
To achieve growth in business with global
competitive edge, providing satisfaction to
the customers, employees, shareholders
and community at large.
 NALCO : LARGEST INTEGRATED
ALUMINIUM COMPLEX IN ASIA
Incorporated in 1981 as Public Sector under Govt. of India.
Leading manufacturer & exporter of Aluminium in the country.
A five star trading house
An ISO 9002 & ISO 14001 Company
Miniratna status by Govt. of India.
Export of Alumina & Aluminium to about 30 countries.
The total Capital Cost of 24080 MINR was funded through
Govt. of India contribution : 12890 MINR
Euro-dollar loan from
a consortium of International Banks : 11190 MINR(Equivalent)
 LANDMARK EVENTS
Foundation-stone laid by Late Smt. Indira Gandhi - March 1981

Commissioning of the Units : September 1985 - March 1987

Commencement of Aluminium Sale - May 1987
Commencement of Alumina Export - Jan. 1988

London Metal Exchange Registration - May 1989

Dedicated to the Nation by Late Shri Rajiv Gandhi - June 1989

Achieved Zero-debt Status - Sept. 1998

 Nalco as on Today
Nalco has implemented a major capacity expansion project of 42000MINR
funded mainly through Internal accruals. (Loans - 3000 MINR)

Initial Expanded Commissioned

Capacity Capacity

Bauxite 2.4 MTPY 4.8 MTPY Dec99

Alumina 0.8 MTPY 1.575 MTPY Mar01

Aluminium 0.230 MTPY 0.345 MTPY Mar03

Power 720 MW 960 MW Feb04

 Nalcos expansion plan

Investment-41000 MINR
Capacity Enhancement-
a) Bauxite Mine: 6.3 MTPY
b) Alumina : 2.1 MTPY
c) Aluminium : 0.46 MTPY
d) Power : 1200 MW
 AUTOMATION POWER

AUTOMATION REQUIRED FOR

1. Electrical Power systems

2. Plant Process systems
3. Management Information systems
Present Automation are the state of the art Man Machine Interface
and Fiber Optic Network that provides a Real time report on all the
key operations
 ILMS (Intelligent Load Management Systems)
Load Shedding
TYPES

Fast Load Shedding on Lossof loads

Load Shedding on Frequency Drop
Slow Load Shedding on Overload

Manual Load Shedding

 Example on Typical Load Management System
Smelter Substation
Operator station RTU/ Controller
Control Room
for Status view
and Control Energy Meters

, Breaker Control with

Grid Incomer inputs Electrical/
Converter

cpp ADSS Cable on

control tower
Energy Meters

6 Kms
room GPS receiver
Dot Matrix Printer ABB Network P a r tn e r FEEDER TERMINAL

O
I
REF541 ABB Network P a r tn e r FEEDER TERMI NAL

O
I
REF541

Line Protection Relays and for Time sync

F
AB B T r an s mi t O y
N e tw o r k P ar t n er

R
L

R
L F
AB B T r an s mi t O y
N e tw o r k P ar t n er

R
L

R
L
Islanding Relays
C C
E E
U aux = 80...265 Vdc /ac Ion= 1/5 A (Io) 1 M R S x xx xx x U aux = 80...265 Vdc/ac Ion= 1/5 A (Io) 1MR S xxxxxx

fn = 5 0 Hz Un= 100/110V (U) 98150 fn= 50Hz Un= 100/110V (U) 98150

In = 1/5 A (I) Uon= 100/110 V (Uo) 950 9 In = 1/5 A (I) Uon= 100/110 V (Uo) 950 9

Hard Copy
Laser Jet Status Inputs of the Breaker Synchronisation Panel
Engineering Station
Printer

2 Electrical/
Converter

Operator station Energy Meters

for Status view RTU/ Controller
and Control

Generator
Inputs/Outputs,
Breaker Control
.
 AUTOMATION FOR RECTIFIERS

Aluminium Smelters demand 100% power

round the clock. Transformers and rectifiers
must perform reliably under most arduous and
demanding duty.

1. Use of Industrial Automation in control of rectifiers

2. Implementation of Closed loop operation
3. Usage of HMI for better understanding
4. Interface with SCADA systems for Real time operation
5. Better protection during faults
 OVERALL SMELTER AUTOMATION SYSTEM

Right from mining of bauxite to casting,

Industrial Automation (IA) is the key to
success.

Metal Extraction Application Type of Automation

Alumina Measure IA
Dry Scrubber Drive IA
Anode Plant Optimize IA
Switchyard Protect IA
DC Conversion Power IA
Smelter Control IA
Ingot Skimming Robotics IA
Casting Operate IA
 Automation in Mines

16 km single flight cable belt system

drive control automation

Introduction of Auto truck despatch

system through GPS
.
Major Automation in Refinery
Process control of Steam
Generation Plant through DCS

Process Control of refinery plant

through DCS
 Benefits of Automation
High quality product
Increase in productivity
Safe and Reliable performance of
the system and equipments
Optimisation of resource inputs
Energy Conservation
Environment protection
Increase in life expectancy of
process plant equipments
High over all efficiency of the plant
RESULTS OF AUTOMATION
Issues related to Automation

-Very fast obsolescence

-Compatibility
-Standardisation
-Cost of Automation