About the Client
The client is a leading aluminum manufacturer, dedicated to optimizing their production processes to reduce fuel consumption and operational costs. They focus on achieving high efficiency in their Twin Chamber Furnace (TCF) and holding furnaces.
Problem Statement
A significant amount of heat is required to melt aluminium and maintain the target temperature of 730 degrees Centigrade. The fuel used in the TCF is Low Sulphur Heavy Stock (LSHS). Currently, the consumption of LSHS in the TCF is 70 liters per ton and in holding furnaces is 20 liters per ton, totaling 90 litres per ton. The client aimed to reduce overall consumption to 85 liters per ton, focusing on reducing TCF consumption to below 65 litres per ton.
Solution
Valiance Solutions developed a comprehensive approach to address this problem by implementing process understanding, data analysis, and operational adjustments:
- Process Understanding: Collaborated with floor staff to understand furnace operations, including melting, holding, regenerative burning, and twin chamber operations. This collaboration ensured a quick understanding and effective communication with the plant team.
- Data Source Identification: Retrieved data from the vendor cloud server, processed it for missing and outlier values, and integrated it into a 1-minute frequency. This meticulous data management allowed for accurate calculation of furnace efficiency and clear performance visualization for the plant team.
- Exploratory Data Analysis: Analyzed operational data and identified that metal temperature often exceeded the target in each melting cycle, which reduced furnace efficiency. Solutions focused on adjusting metal overheating to increase efficiency.
Outcome
- Oil Savings: Implemented solutions to avoid metal overheating, achieving oil savings of 5 liters per ton. This initiative led to cost savings of about $100,000 per annum per plant.
- GHG Emission Reduction: Indirect benefits included a 3% reduction in GHG emissions from the furnaces. This solution was implemented by adjusting the SOPs in the plant, enhancing sustainability.
- Future Scope: The solution was successfully implemented at the client’s plant. The next phase aims to predict total variations in a melting cycle and prescribe an oil flow rate to achieve the target temperature efficiently.
This detailed case study highlights Valiance Solutions’ commitment to leveraging data-driven insights and operational expertise to drive efficiency and sustainability in industrial processes. By integrating comprehensive data analysis with practical adjustments, we enabled the client to achieve significant cost savings and environmental benefits.
