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A Climate-friendly Promise By Sterlite
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Sterlite copper is the first prize sector copper smelter in India. It has integrated operations extending into mines in Australia to smelter, refinery and rod operations in India. Sterlite correct produces approximately 2 percent of the world's copper production. It has revenue which is in excess of Rs. 19,000 crore. It is also the third largest company in Tamilnadu, contributing about 3 percent to the state's Gross Domestic Product (GDP). It is also touted to be the world's first custom Copper smelter with Zero liquid discharge system since the inception of the plant. Sterlite copper is also the world's first certified mining and metal company in asset management system. It provides direct employment to about 2800 workers and employs 20,000 indirectly. It is also the largest private sector company using the port, and contributes about 8 percent to the port's annual revenue.
The company has initiated various innovative projects. Oxygen plant is one of the famous one. Oxygen Plant in Sterlite Copper uses the Gas Separation System through Temperature Swing Adsorption(TSA) technique. The atmospheric air is passed to adsorbent with high Nitrogen affinity at lower temperature for a specified period to adsorb Nitrogen in air. Pure Oxygen is received through the Gas separation column for further processing. At a certain point the adsorbent is saturated and regeneration by desorption is required. For this the temperature is raised to 240 oC to desorb the adsorbed components ,the set point has been optimized to 200°C which is sufficient for the process.
Optimisation of pet coke consumption is another one started by sterlite copper. Pet coke is used in ISA smelting furnace in order to increase the energy level in the furnace. Pet coke is consumed due to two different reasons, primarily to increase the energy level in the blend and also consumed when the high volume of reverts treated in furnace. Revert is a material, formed due to solidification of liquid Matte/Blister during its transfer. Before this project revert generation was 280MT/day after implementation it reduced to 180 MT/day.
Next one is the refinery current efficiency. Electrorefining of Copper(Cu) from 99.7% Cu anode to 99.99% Cu cathode is driven through Electrolysis reaction by using DC power through rectifiers. The ratio of actual copper deposit obtained as product to the theoretical deposit calculated as per Faraday’ law is measured as a Key indicator of process called Current Efficiency (CE%). Physical characteristics of electrode and chemical characteristics of anode and circulation electrolyte temperature & impurities(soluble & insoluble) are factors affecting CE.Continuous Improvement project taken by Refinery team to increase the CE from current level of 97.92% to 98.5% and achieved by correction of verticality of SS Cathode plates, Anode verticality control through anode lug mill angle correction, introduction of verticality measurement tools and electrolyte insoluble impurity control by 100% decant volume filtration in circulation.
Also, Sterlite copper has its own entertainment and carbon policy. Also, the company creates awareness about energy and its commitments to global climate friendly techniques. Awareness is created in the following ways:
National Energy Conservation week celebration with pledges and awareness program for contract and company staffs.
Circulating energy conservation related article across the plant through mail Displaying energy conservation posters in desktops.
Distributed LED lights to employees and local communities
Crossword puzzle on energy conservation for the employees
Distributed the energy awareness pen to all the employees & contractors
Creating awareness through using the common vehicle for transportation.
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