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nalco smelter ppt final

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aakarsh prasad

on 14 June 2013

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Transcript of nalco smelter ppt final

A Presentation on NALCO SMELTER PLANT
Incorporated in 1981, as a public sector enterprise of the Government of India National Aluminium Company Limited (Nalco) is Asia's largest integrated Aluminium complex, encompassing bauxite mining, alumina refining, Aluminium smelting and casting, power generation, rail and port operations. Commissioned during 1985-87, Nalco has emerged to be a star performer in production, export of alumina and Aluminium, and more significantly, in propelling a self-sustained growth.
Introduction.
1975
Discovery of bauxite along eastern coast.
1981
foundation stone
laid by Mrs. Indira Gandhi
1987
sale of aluminium
starts
2004
first phase
expansion complete
2008
granted navratna
status.
2011
2nd phase expansion
complete
2012
refinery upgradation
starts
KEY MILESTONES AND EVOLUTION OF NALCO
SMELTER PLANT : INTRODUCTION
The 3,45,000 tpa capacity Aluminium Smelter is located at Angul in Orissa. Based on energy efficient state-of-the-art technology of smelting and pollution control, the Smelter Plant is in operation since early 1987.
Presently, the capacity is being expanded to 4,60,000 tpa.
INTRODUCTION (contd.)
Advanced 180 KA cell technology
Micro-processor based pot regulation system
Fume treatment plant with dry-scrubbing system
Integrated facility for manufacturing carbon anodes
4 x 35 tone and 4 x 45 tone furnaces and 2 x 15 tph and 2 x 20 tph ingot casting machines
4 x 45 tonne furnaces and 2 x 9.5 tph wire rod mills
2 x 45 tonne furnaces and 60/42 per drop billet casting machine
26,000 tpa strip casting machines
2 x 1.5 tonne induction furnace with a 4 tph alloy ingot casting machine
DESPATCH
Spark
Alumina from Damanjodi
Fume treatment plant
POT LINE ELECTROLYSIS.
CAST HOUSE
GREEN ANODE
CARBON AREA
ANODE BAKING
Spark
RODDING SHOP
AC TO DC
Captive power
plant
CARBON AREA
The carbon area at NALCO basically provides carbon anodes to the potrooms for use in metal extraction by the hall herault process. It consists of three subdivisions i.e. the Green Anode Plant, The anode production facility includes crushing equipment for the production of anode paste and equipment for classifying coke before mixing it with pitch in a mixer.it also contains a vibro-compacter , open furnace for baking, equipment for rodding of baked anodes on aluminium steel stem-brackets and treatment of the used assemblies(anodes/butts) coming back from potlines.
Anode Baking Furnace, and Rodding Shop.
CARBON AREA: RAW MATERIALS.
1.Calcined Petroleum Coke
2. Coal Tar Pitch
3. Baked Scrap
4. Green Scrap
POTLINE.
Pot Line At A Glance:
•Technology : AP-18
•Advanced 180 KA cell technology
•No Of Pot Lines : 3
•No Of Pots : 240 x 4 = 960
•Anodes : Prebaked
•Cathodes : Semigraphite
•Production Capacity : 3,45,000 tpa
• Environmental Control : Dry Scrubbing System (FTP)
•Alumina Feed Regulation : ALPSYS (Point Feed)
•Micro-Processor Based Pot Regulation System
POTLINE.
Electrolysis Requirements
Alumina - 02.5 % Anode
Prebaked carbon blocks made from Pitch and Calcined Pet. Coke fitted with Anode Stem from Carbon Area
Cathode :Imported carbon blocks and then fitted into pots at PCRS
Electrolyte
Cryolyte - 80 %
Alu.Fluoride - 11.50 %
Cal.Fluoride - 05 %
Others - 1.00 (Na2O, FeXO3, SiO2, TiO2, V2O5)

Anode:
Anodes are made of Carbon ( CP Coke & Pitch ) & Baked At 11000c
Anodic Reaction : Reaction At +ve Pole
2 Al2O3 + 3C = 4 Al + 3 CO2
Anodes are consumed continuously & replaced in a Scheduled manner in every 68/72 shifts.
Cathode:
Cathodes Are Made Of Carbon acts as Receptacle for
Liquid Aluminium ( -ve Pole )
Types Of Cathode : Anthracite
Nalco : Semi-graphite/Graphite
12 Blocks placed in a iron shell and ramming is done using
Ramming Paste (small /large Joint)
Type Of Cathode decides amount of amperage
POTLINE.

Tapping Schedule:
Tapping is done in every 32 hrs from a pot.
Approximately 1.95 - 2.0 tons of molten aluminium is tapped from each pot.
Quantity of metal to be tapped varies based on pot condition.
Metal tapping recommendation is based on metal height.
Metal despatch schedule is based on metal planning prepared by Cast house.
More than 80% metal produced is of 99.7%.
Anodic & Cathodic area is fixed for a pot & related to pot design.
Bath Resistance, R = x ℓ/ a
R- Resistance Of Electrolyte (bath.)
- Specific Resistance (Depends On Bath Chemistry)
ℓ - ACD
A - Anodic Area
CAST HOUSE
Cast house gives shape to molten aluminium received from pot lines after refining/Alloying as per customer’s requirement.
CASTING FACILITIES:
Ingot casting machines
Wire rod mills
Billet casting facilities
Strip casting facilities
MAJOR ACTIVITIES AT CAST HOUSE-
Skimming
Fuel firing for temperature
Melting
Scrap melting
CAST HOUSE
MAJOR PRODUCTS MANUFACTURED AT CAST HOUSE ARE-
Ingots (20kg size)
Sow Ingots (650kg size)
Wire rod/Alloy wire rod (7.6mm/9.5mm/12mm/15mm diameter)
Billet of 6 meters length
cut billet as per customer requirement
Alloy Ingots-10kg size
Bus Bar
Anode Stem
CAST HOUSE
FACTORS ON WHICH PRODUCTIVITY DEPENDS-
HFO Consumption
Furnance in operation
Idle time
Plant management
Scrap generation
LDO consumption
PRODUCTION HIGHLIGHTS

1.LONGEST CONTINUOUS RUN OF 18 DAYS IN STRIP CASTER
2.ACHIEVEMENT OF RATED CAPACITY IN CASTING LINE NO. 1 IN JAN’06 WITH HIGHEST PRODUCTION OF 841 MT OF CAST STRIP
OF 1270 MM WIDTH
3.ALLOY CASTING & ROLLING OF 1050, 1100, 8011 AND 3003 ALLOYS HAVE BEEN SUCCESSFULLY DONE
CARBON AREA
Typical coke characteristics are as follows:-
a.Ash Content: 0.5 % max.
b.Moisture: 0.3 % max.
c.Hg Density: 1.70 gm/cc min.
d.OS 4.75 mm: 35 % min.
e.US 0.3 mm: 15 % max.

POTLINE
Electrolysis Requirements
Alumina - 02.5 % Anode
Prebaked carbon blocks
Cathode :Imported carbon blocks and then fitted into pots at PCRS
Electrolyte

CAST HOUSE
QUALITY ASPECTS OF ROLLED PRODUCTS
COMPOSITION
TEMPER
THICKNESS WITHIN TOLERANCE
LENGTH/ WIDTH WITHIN TOLERANCE
FLATNESS
SURFACE QUALITY

CONCLUSION
Nalco is one of the biggest Aluminium producing industry in the country. bauxite for the angul plant is mined from damanjodi. the cpp provides necessary power. the smelter plant is divided into 3 main categories i.e. potlines, carbon area and cast house.
the total production capacity is 460000 tpa.
The End.
Thank you.
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