The Carbon Operations Department has successfully implemented 18 out of 23 generated ideas, achieving a total direct cost saving of $21,291 per month.

Enhancing Combustion Efficiency

In standard firing operations, the three essential elements for effective combustion—fuel (RFO), oxygen (draft/air), and heat—must be balanced correctly. To optimize combustion in the baking furnace, it’s crucial to prevent excess air from infiltrating the combustion chamber. An innovative solution was introduced to blanket not only the first but also the second green section ahead of each operating fire, minimizing excess air infiltration. This improvement has enhanced combustion efficiency and reduced fuel consumption.

Reducing Thermocouple Usage

As part of the SII programme, a method was developed to plant a thermocouple in the baking section using a specialized insert, reducing thermocouple usage by approximately 8 pieces per month and yielding average monthly savings of $2,028.

Cost-Effective Sowing Mold Improvements

An additional innovation involved partitioning the sow mold with a thick steel plate and lining it with castable refractory material. This modification has generated significant savings, reducing repair costs by an average of $6,700 per month.

These initiatives reflect the Carbon Operations Department's commitment to improving efficiency, reducing costs, and leveraging innovative ideas for sustainable operations.