Introduction of AluminiumSector under

PAT Scheme
Sudhan Ramkumar
Bureau of Energy Efficiency
 Indian Aluminium Industry

 India is one of the largest Aluminum

producer in the world.
 The main source for the aluminium
industry is coal and electricity.
 Energy cost accounts for about 45% of the
total manufacturing cost in some of the
aluminum plants and coal accounts for 30-
40% of the total production costs.
 Indian Aluminium Industry (contd.)

 Because of the complexities, it becomes

extremely difficult to come to a common model
to arrive at standardized SEC per ton.
 Considering all these situations, the conversion
factors and best possible combination and
categorization have been worked out so that no
Designated Consumer may have any grievance
on the targets set out
 While setting targets , units best in the group as
reference and then worked out targets for
others.
Indian Average Vs Global best

12 %
6%

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 Grouping of DCs

Aluminium plants
(10 DCs)

Based on Process

Refinery Smelter Integrated Cold Sheet

 PAT – 1 Overview
Sr Sector No. of Reported Energy National Energy Saving Targets under PAT (%)
No Identified Energy Saving (2012-15)
DCs PAT Consumptio Targets
Cycle-1 n PAT Cycle-1 under PAT
(million toe) Cycle-1
(million toe)
1 Aluminium 10 7.71 0.456
2 Chlor-Alkali 22 0.88 0.054
3 Textile 90 1.2 0.066
4 Pulp & 31 2.09 0.119
Paper
5 Iron & Steel 67 25.32 1.486
6 Fertilizer 29 8.2 0.478
7 Cement 85 15.01 0.816
8 Thermal 144 104.56 3.211
Baseline Period:
Power
2007-08, 2008-09, 2009-10
Plants
Total 478 164.97 6.686
Assessment year: 2014-15

M&V period: April-2015 to Jun- 6

 DC Status In Aluminum Sector

 Threshold Limit for DC Selection : ≥ 7500 MTOE per annum

 Total No. of identified DCs : 10
 Integrated Unit : 01
 Refinery Unit : 04
 Smelter Unit : 04
 Cold Sheet : 01

 Baseline Energy Consumption : ~7 mMTOE by all the DCs

 Target Reduction : 0.456 million TOE

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Refinery Plant (GtG Boundary)

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 PAT Cycle – 1 Achievement in Aluminium sector
Refinery Sector
1.2 Refinery Sub – sector
Descriptions BY AY % Change Remarks
1
SEC (TOE/Ton) 0.3905 0.3035 2 2 % Reduction in Refinery section
0.8

0.6

0.4

0.2

0
1 2 3 4

Assessment Year Baseline year Smelter Sub – sector

Descriptions BY AY % Change Remarks
Smelter Plant SEC (TOE/Ton) 5.343 5.077 5% 5 % Reduction in Smelter section

14

12

10
Integrated Sub – sector
8 Descriptions BY AY % Change Remarks
6 SEC (TOE/Ton) 5.858 5.512 6% 6 % Reduction in Integrated Plant

0
Cold Sheet Sub- Sector
1 2 3 4
Descriptions BY AY % Change Remarks
Assessment year Baseline year SEC (TOE/Ton) 0.183 0.172 6% 6 % Reduction in Cold Sheet Plant
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 Major Initiative in PAT – 1 Cycle

• Adoption of Slotted Anode in Pots by Smelter Plants

• Reduction of Voltage Drops, by anode buffing

• Improvement of current efficiency of aluminium smelting process

• Implementation of Energy Efficiency projects, such as VFDs retrofitting, LED

implementation.

• Replacement of Old Pumps with Energy Efficient pumps in Refinery section

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 PAT Cycle – II

No. of Annual Energy Share Apportioned Energy

S.No Sectors Identified Consumption Consumption Reduction For PAT
DCs (Million toe) (%) Cycle-1 (Million toe)

Power
1 (Thermal) 154 120.16 52.99% 3.13
2 Iron & Steel 71 40.44 17.83% 2.14
3 Cement 111 21.43 9.45% 1.1
4 Aluminium 12 10.66 4.70% 0.57
5 Fertilizer 37 8.25 3.64% 0.446
6 Paper & Pulp 29 2.68 1.18% 0.15
7 Textile 99 1.48 0.65% 0.087
8 Chlor- Alkali 24 1.77 0.78% 0.101
9 Refinery 18 18.5 8.16% 1.1
Electricity
10 Distribution 44
Companies
11 Railway 22 1.39 0.61% 0.033
Total 621 226.76 8.869
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 PAT Cycle II Target

 Total No. of identified DCs : 12

 Integrated Unit :1
 Refinery Unit : 5
 Smelter Unit : 5
 Cold Sheer Plant : 1

 Baseline Energy Consumption : ~10 mMTOE by all the DCs

 Target Reduction : 0.57 million TOE

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Thank You

Sudhan Ramkumar
Bureau of Energy Efficiency

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