EXCEL EXC ELL L ENC ENCE E IN ENERGY ENERGY MANAGEMENT
BY ASIA A SIAN N PAINTS PA INTS LTD. L TD. PENTA DIVISION, CUDDALORE.
AB A B OUT US … Asian
Paints is India’s largest Paint Company and ranked among the Top 10 decorative coating companies in the World.
We have 28 Manufacturing facilities across the World servicing Consumers in 65 Countries.
In India, we have 9 plants manufacturing coatings and 2 plants manufacturing chemicals. Our Unit manufacturing Pentaerythritol is located at Cuddalore, Tamilnadu.
Penta Division is accredited with ISO 14001 and OHSAS 18001 certification and manufacturers following chemicals : Various grades of Pentaerythritol
Sodium Formate
Formaldehyde
We have an enviable reputation for f or innovative Energy conservation practices which helped us to bring down the specific energy consumption, helping the division survive.
PROCESS
Involves precisely controlled Reaction of Formaldehyde and Acetaldehyde in the presence of Caustic soda.
The product of the Reactor is concentrated by Evaporation followed by Crystallization and separation in a Vacuum belt filter.
The product of Vacuum belt filter is purified, dried and sent for packing.
PROC PR OCES ESS S BLOC BL OCK K DI DIA A GR GRA AM Fa Aa
Reaction
Ca
For Formaldehyde and Methanol Recovery
Knock Down Tank
Crude Vacuum Crystalliser
Five Effect Evaporator
Stripper
Crude Belt Filter
Deionizer / Carbon columns
Distillation Column
Crude Mother Mother Liq uor
TO AIR
Crystalliser Pure Vacuum Crystallizer
Tech PE Drier
Tech PE Silo
Tech PE Bagging
TO AIR AIR
Sodium Formate Drier TO AIR
Tech Dissolver
Crystalliser
Mech Sieving
Mono PE Drier
Mono PE Silo
Mono PE Bagging
TO AIR
PE : Pe Penta nt aeryth ry thri rito toll
Di PE Drier
Di PE Silo
Di PE Bagging
Sodium Formate Bagging
ENERGY COSTING Energy Cost accounts for 19% of the total manufacturing cost and 48% of the plant overheads in FY 2011-12. Working towards achieving zero grid power consumption
Electrica lectri call Energ Energyy Cost Therm Therm al Energy nergy Cost 100 100 80
24.4
5.9
4.8
60 40
The Co-Gen system generates required Electrical energy. Cost of imported Energy from the grid alone is captured as Electrical energy cost.
75.6
94.1
95.2
2010-11
2011-12
20 0 2009-10
ENERGY CONSER CONSERV VATION A CTIVITIES 2009 t o 2012 Sl. No.
1.
2.
3.
4.
Activity (2009-10) (2009-10)
Investmen t (RL)
Replacing Crude Belt Filter (CBF) Vacuum pump with Energy efficient pump
1.1
Replacing Pure Belt Filte lter (PBF) Vacuum pump with Energy efficient pump
0.96
Replacing the low pressure Boiler of 20.5 KSC Pressure, 14 TPH capacity and low Efficiency Turbine with high pressure Boiler of 45 KSC Pressure and High Efficiency Turbine to increase the power generation from the Back pressure Turbo Alternator Alternator for the same Steam flow.
749
Reducing 1500 KVA Turbo Alternator frequency frequency from 50 Hz to 48.5 Hz
Reduction in specific steam consumption in MT/TPE
Reduction in specific power consumption in kwhr /TPE
Power savings per annum (Units in Lacs)
Fuel (COAL of 6000 kcal) Saving per annum (MT)
---
15.4
0.73
---
Cost Saving Per annum (RL) Saving as % of energy bill 3.27
0.41 % ---
13.7
0.65
---
2.9
0.37 % ---
---
36.29
---
163.3
20.6 % 0
---
108.4
5.09
---
22.93
2.9 %
S.No
5.
6.
7.
8.
Activity (2009-10)
Investment (RL)
Increasing the production/Rxn. production/Rxn. by Increasing the Initial Formaldehyde concentration from 10.1 to 10.5 leading to reduction in energy consumption (Reduction in water input into the process)
0
Replacement of Pressure Reducing Station (PRV for 45 to 5.2 KSC) with Thermo compressor for increasing power generation through turbine. (Even though this activity has resulted in an additional power generation of 168 KW which is around 15% of our total power consumption, the same will not get reflected in Specific energy consumption)
7.0
Firing of Waste gas containing Hydrogen and traces of methanol from Formaldehyde plant in boiler for generating steam
1.6
Installation of 2Nos of 18.5 KW VFD for Cooling Tower
1.6
Reduction in specific steam consumption in MT/TPE
Reduction in specific power consumption in kwhr /TPE
Power savings per annum (Units in Lacs)
Fuel (COAL of 6000 kcal) Saving per annum (MT)
---
10.29
0.48
---
Cost Saving Per annum (RL) Saving as % of energy bill 2.18
2.7 %
---
---
13.55
---
60.96
7.67 % ---
---
---
961
45.17
5.69 % ---
15.44
0.73
---
3.99
Sl.
Activity (2010-11) (2010-11)
No
9.
10. 10.
11.
Investment (RL)
Reducing Cooling Water circulation flow rate by replacing 3 Nos. of Shell and Tube Heat Exchangers with a single PHE in distillate line going to Reactor. Reactor.
3.75
Opti Optimi miza zati tion on of Batc Batch h cyc cycle le time time in Vacuum Crystallizer by Removing the Cyclone Cyclone separator which was a part of imported crystallizer.
0
Incr Increa easi sing ng the the Pow Power er thro throug ughp hput ut across the Turbo Alternator (Back pressure Turbine) by increasing the steam drawn through the Turbine and simultaneously reducing the HP steam consumption which is bypassing the turbine. The medium pressure requirement is reduced from 5.2 to 4.8 KSC by increasing i ncreasing the Heat transfer area of the Re-boiler. However the overall steam consumption remains the same. (Even though this activity has resulted in an additional Power Generation of 41.25 KW, the same will not get reflected in Specific Power consumption. Indirectly the power drawn from the TNEB grid has reduced to that extent.)
4.62
Reduction in specific steam consumption in MT/TPE
Reduction in specific power consumption in kwhr /TPE
Power savings per annum (Units in Lacs)
Fuel (COAL of 6000 kcal) Saving per annum (MT)
0.037
19.4
1.05
32.63
Cost Saving Per annum (RL) Saving as % of energy bill
6.29
0.68 % 0.202
---
---
176.8
8.48 0.92 %
---
---
3.33
5.8
14.97
1.63 %
Sl.
Activity (2010-11) (2010-11)
No
12.
13. 13.
14.
Investment (RL)
Replacing 15 150 W, HP HPSV Street light fittings with LED fittings of 30W (10 Nos)
0.95
Repla eplac cing ing Ele Elec ctric tric stor torage age Water heaters with Solar water heater in canteen application.
2.2
Ins Install talla ation tion of a Bo Boiler iler steam team Air pre-heater in order to balance the plants thermal energy and Electrical energy requirement for efficient operation of Cogeneration system. This activity resulted in elimination of steam venting on account of mismatch between thermal and Electrical energy requirements of the plant.
2.5
Reduction in specific steam consumption in MT/TPE
Reduction in specific power consumption in kwhr /TPE
Power savings per annum (Units in Lacs)
Fuel (COAL of 6000 kcal) Saving per annum (MT)
---
1.05
0.06
---
Cost Saving Per annum (RL) Saving as % of energy bill
0.26 0.03%
---
4.87
0.26
---
1.18
0.13 % ---
---
---
552
28.69
3.1 %
Sl.
Activity (2011-12) (2011-12)
No
15
16
17
Investment (RL)
Redu educing ing the the plan plantt oper peratio ation n days per month from 28.08 days to 26.75 days for achieving the consented production of 450 MT/month by1. Optimising the reaction batch cycle time from 45 min to 40 min by increasing the reactant flow rate without affecting the reaction performance.2. performance.2. Reducing the batch cycle time of T148 (Tech dissolver) by 15 min. by simultaneous pumping of its feed streams.
0.0
Reducing the steam consumption in Formaldehyde plant by optimizing the conversion of Methanol to Formaldehyde in Reactor by reducing the concentration of feed methanol.
0.0
Reducing ing th the wa water in ingress into the process by automation of Crude Belt Filter cake wash.
0.9
Reduction in specific steam consumption in MT/TPE
Reduction in specific power consumption in kwhr /TPE
Power savings per annum (Units in Lacs)
---
57.99
3.13
Fuel (COAL of 6000 kcal) Saving per annum (MT)
Cost Saving Per annum (RL) Saving as % of energy bill
14.09
1.4 % 0.299
---
--
261.1
13.86
1.4 % 0.179
---
---
155.64
8.32 0.83 %
Sl.
Activity (2011-12) (2011-12)
No
18
19
20
21
Investment (RL)
Reduction in specific steam consumption in MT/TPE
Reduction in specific power consumption in kwhr /TPE
Power savings per annum (Units in Lacs)
Fuel (COAL of 6000 kcal) Saving per annum (MT)
--
16.43
0.89
--
Cost Saving Per annum (RL) Saving as % of energy bill
3.99
Reduc ducing ing Pow Power consum nsumpt ptio ion n of Lobe blower for conveying Off gas from Formaldehyde plant to Boiler by reducing the pressure drop across the line.
2.75
Increasing the Power generation per MT of steam across the TG (Turbo Generator) by reducing the pressure drop across the governor valve. (By way of widening the governor opening limits)
0.0
Reducing the Power consumption in ETP aerator by providing VFD with necessary speed control system based on COD level in aerator.
0.9
Repl Repla acing ing 150 W, HPSV HPSV Str Street light fittings with LED fittings of 45W (10 Nos)
0.99
Other miscellaneous projects over the past three years (14 projects)
8.76
5.13
108.2
39.14 3.86%
789.6
77.49
2062
460.8
TOTAL
0.4 % ---
---
1.51
---
6.8
0.69 % ---
4.87
0.26
---
1.18
0.12 % ---
0.93
0.05
---
0.23 0.02 %
Sl.
Activity (2011-12) (2011-12)
No
18
19
20
21
Investment (RL)
Reduction in specific steam consumption in MT/TPE
Reduction in specific power consumption in kwhr /TPE
Power savings per annum (Units in Lacs)
Fuel (COAL of 6000 kcal) Saving per annum (MT)
--
16.43
0.89
--
Cost Saving Per annum (RL) Saving as % of energy bill
3.99
Reduc ducing ing Pow Power consum nsumpt ptio ion n of Lobe blower for conveying Off gas from Formaldehyde plant to Boiler by reducing the pressure drop across the line.
2.75
Increasing the Power generation per MT of steam across the TG (Turbo Generator) by reducing the pressure drop across the governor valve. (By way of widening the governor opening limits)
0.0
Reducing the Power consumption in ETP aerator by providing VFD with necessary speed control system based on COD level in aerator.
0.9
Repl Repla acing ing 150 W, HPSV HPSV Str Street light fittings with LED fittings of 45W (10 Nos)
0.99
Other miscellaneous projects over the past three years (14 Nos.)
8.76
5.13
108.2
39.14 3.86%
789.6
77.49
2062
460.8
TOTAL
0.4 % ---
---
1.51
---
6.8
IRR 28.1% 0.69 % ---
4.87
0.26
---
1.18
0.12 % ---
0.93
0.05
---
0.23 0.02 %
INTERNATIONAL NORMS VIS-À-VIS OUR PERFORMANCE NORMS**
ACTUALS 2011-12
PERFORMANCE
Specific Steam consumption (MT)
20
19.56
2.2 %
Specific Power consumption (Kwhr)
2200
1363
38 %
** Norms specified specifi ed by the Technology echnol ogy provider M/s.Hercules M/s.Hercu les Inc.,USA. Inc.,USA.
IMPACT ON SPECIFIC POWER / STEAM CONSUMPTION Details
Steam Consumption in MT
Power Consumption in Kwhr
Specific consumption during 1999
25.03
2643
Specific consumption during 2011-12 2011-12
19.56
1363
A wh w h o p p i n g r edu ed u c t i o n o f 22 % in Stea Steam Consum Cons umpt ptio ion n 48 % in Powe ow er Consump Consu mptition on
TRENDTRE ND- SPE SPECIF CIFIC IC POWER POWER CONSU CONSUMPT MPTION ION 3000 2800 2600
2850 2750 2694 2643 2400
2400
2400
2431
2200
2200
2150 1975
2090
2000
1929
1800
1825 1650 1695
1600
1550 1550 1540 1540
1587
1554 1400
1510 1450
1548 1521 1489
1380 1421
1391 1363
1200 96-97 96-97 97-98 98-99 98-99 99-00 00-01 00-01 01-02 01-02 02-03 03-04 03-04 04-05 05-06 05-06 06-07 07-08 07-08 08-09 08-09 09-10 10-11 10-11 11-12
ACTU ACTUALS TARGE TA RGETS TS
2850
2694
2643
2431
2200
2090
1929
1695
1587
1554
1548
1521
1489
1421
1391
1363
2750
2400
24 2400
21 2150
1975
18 1825
1650
15 1550
1550
15 1540
15 1540
1510
14 1450
1380
A wh w h o p p i n g r edu ed u c t i o n o f 52% in i n Pow Po w er Con Co n s u m p t i o n
TRENDTRE ND- SPE SPECIF CIFIC IC POWER POWER CONSU CONSUMPT MPTION ION
1550 1500
1510
1450 1450 1400
1421
Target 1391
1350
1380
Ac A c t u al 1363
1300 1250 2009-10
2010-11
2011-12
TREND TRE ND - SPE SPECIF CIFIC IC STEAM STEAM CONSUMP CONSUMPTIO TION N 36
36.00 34.00
33.30
32.00
34 32
30.30
30.00
30 27.80
28.00
27.25
28
29
26.00
27
25.03 27
26 23.37
24.00
24 22.00
24 21.04 22.75
22 20.01 19.18 19.10 20.75
20.00
21
19.20 19.20 19.25 19.25 19.00 19.08 20
20
20
18.00
19.5
19.81 19.56 20 19.8 19.6
18
18.35 16.00
16 9696-
9797-
9898-
9999-
0000-
0101-
0202-
0303-
0404-
0505-
0606-
0707-
08-
0909-
1010-
1111-
97
98
99
00
01
02
03
04
05
06
07
08
09
10
11
12
33.30 30.30 30.30 27.80 27.80 27.25 27.25 25.03 25.03 23.37 23.37 21.04 21.04 19.18 19.18 19.10 19.10 20.01 20.01 19.20 19.20 19.25 19.25 19.00 19.00 19.08 19.08 19.81 19.81 19.6 19.6 ACTUALS ACTUALS 33.30 TARGETS
29
27
27
24
22. 8 20. 8 18. 4
21 21
20
20
20
19. 5 19. 8 19. 6
A wh w h o p p i n g r edu ed u c t i o n o f 41.3 % in i n Steam St eam Con Co n s u m p t i o n
TREND TRE ND - SPE SPECIF CIFIC IC STEAM STEAM CONSUMP CONSUMPTIO TION N 20 19.5 19
19.8 19.81
19.5
19.6 19.56
19.05
18.5 18 17.5
*
17
Target
*
18.8
18.6
2010-11
2011-12
Ac A c t u al
16.5 16 15.5 15 2009-10
We have commissioned a Zero liquid Discharge system comprising of Multiple Effect Evaporator and ATFD ATFD leading to increase in Steam consumption.
PROC PR OCES ESS S BLOC BL OCK K DI DIA A GR GRA AM Fa Aa
Reaction
Ca
For Formaldehyde and Methanol Recovery
Knock Down Tank
Crude Vacuum Crystalliser
Five Effect Evaporator
Stripper
Crude Belt Filter
Deionizer / Carbon columns
Distillation Column
Crude Mother Mother Liq uor
TO AIR
Pure Vacuum Crystallizer
Tech PE Drier
Crystalliser
Bottlenecks Tech PE
Tech PE Silo
TO AIR AIR
Bagging Sodium Formate Drier TO AIR
Tech Dissolver
Crystalliser
Mech Sieving
Mono PE Drier
Mono PE Silo
Mono PE Bagging
TO AIR
PE : Pe Penta nt aeryth ry thri rito toll
Di PE Drier
Di PE Silo
Di PE Bagging
Sodium Formate Bagging
Innova nnovative tive proje project ct – 1 Reduc ducing ing the Pla Plant nt opera operatin ting g da d ays by opt optimi imizzing the cycle cyc le tim time e of Batch ope op era ratio tions. ns. Conc once epts :
Increasing the Reaction batches/day by optimizing the Reaction Batch cycle time.
Increasing the Mono Pentaerythritol (PE) batches/day by optimizing the processing time.
System:
The process of manufacturing of PE starts with a batch reaction involving Formaldehyde, Acetaldehyde and Caustic solutions. By optimizing the batch cycle time of reaction, we could increase the reaction batches/day, thereby reducing the number of plant operating days.
In the manufact manufacturing uring of of Mono PE – the batch batch cycle cycle time of Batch Batch evaporation was optimized by which the number of batches/day was increased.
Innova nnovative tive proje project ct – 1 Reduc ducing ing the Pla Plant nt opera operatin ting g da d ays by opt optimi imizzing the cycle cyc le tim time e of Batch ope op era ratio tions. ns. Acc t i v i t y (A A (A). ). Opt Op t i m i zat zatii o n o f Reac Reactt i o n t i m e:
Conducted Pilot reactor studies.
Sample output analyzed every 5 minutes and compared with standards.
By increasing the rate of addition of the reactants to the Reactor without affecting the kinetics of the reaction, the Reaction batch cycle time was reduced by 5 minutes per reaction (Reaction time has got reduced to 40 minutes from 45 minutes).
Necessary controls exercised to prevent the side reactions.
Exothermic reaction was controlled by adequate cooling.
After
successful implementation of this project, project, average Reaction batches per day got increased to 18.5 from 17.5.
Duration in minutes
Before CW O/L CW I/L CHW O/L CHW I/L
Acetaldehyde Caustic Formaldehyde
Chilled water to PHE
10
Cooling water to PHE
35
React eactio ion n Time 45 Mins Reactor
P‐101
Duration in minutes
Af A f t er CW O/L CW I/L CHW O/L CHW I/L
Acetaldehyde Caustic Formaldehyde
Chilled water to PHE
15
Cooling water to PHE
25
Reaction Time im e 40 40 Min Minss Reactor
P‐101
Innova nnovative tive proje project ct – 1 Reduc ducing ing the Pla Plant nt opera operatin ting g da d ays by opt optimi imizzing the cycle cyc le tim time e of Batch ope op era ratio tions. ns. Acc t i v i t y (A A (A): ): Opti ptimiza mizatio tion n of Rea Reacti ction on Ba B atc tch h cycle cy cle time Before
After
1
Reaction time
45 min.
40 min.
2
Reaction batches per day
17.64
18.54
3
Penta Production per day
16.03 MT
16.82 Mt
4
Consented Limit
450 MT/month
450 MT/month
5
No of days of Operation
28.08 days
26.75 days
Innova nnovative tive proje project ct – 1 Reduc ducing ing the Pla Plant nt opera operatin ting g da d ays by opt optimi imizzing the cycle cyc le tim time e of Batch ope op era ratio tions. ns. Acc t i v i t y (B A (B). ). Opt Op t i m i zat zatii o n o f B at atcc h ev evap apo o r at atii o n :
By implementing the system of simultaneous pumping of two feed streams for evaporation, the batch evaporation cycle time has got reduced by 30 minutes per batch, because of which the number of batches per day has got increased.
Flow meters with integrators were installed in both feed streams in which the required quantity of feed were set and batch pumping was done in auto mode because of which the time delay due to manual pumping of two streams one by one was eliminated completely.
Innova nnovative tive proje project ct – 1 Reduc ducing ing the Pla Plant nt opera operatin ting g da d ays by opt optimi imizzing the cycle cyc le tim time e of Batch ope op era ratio tions. ns. Before
80%
Tota ot al Filli Fil ling ng Time im e 55 55mins mi ns
50%
Tech Dissolver
20%
Pumping Time 30mins
Pure ur e Pe Penta nt a Sol Solut utio ion n
Pumping Time 25mins
Recy cycl cle ed Pent Penta a Solut ol utio ion n
Innova nnovative tive proje project ct – 1 Reduc ducing ing the Pla Plant nt opera operatin ting g da d ays by opt optimi imizzing the cycle cyc le tim time e of Batch ope op era ratio tions. ns. Af A f t er
80%
FIT
FIT
Tota ot al Fillin Fill ing g Time im e 30 30 mins min s Tech Dissolver
Pure ur e Pe Penta nt a Sol Solut utio ion n
20%
Recy cycl cle ed Pent Penta a Solut ol utio ion n
Innova nnovative tive proje project ct – 1 Reduc ducing ing the Pla Plant nt opera operatin ting g da d ays by opt optimi imizzing the cycle cyc le tim time e of Batch ope op era ratio tions. ns. Activity (B): Optimization of Tech Tech dissolver batch cycle time Before
After
1
Feed streams pumping time
55 min
30 min
2
Tech Dissolver Ba Batch tches per day
4.17
4.50
3
Batch Cycle time
350 minutes
325 minutes
4
Penta Production per day
16.03 MT
16.82 Mt
5
Consented Limit
450 MT/month
450 MT/month
6
No of days of Operation
28.08 days
26.75 days
Innova nnovative tive proje project ct – 1 Reduc ducing ing the Pla Plant nt opera operatin ting g da d ays by opt optimi imizzing the cycle cyc le tim time e of Batch ope op era ratio tions. ns. Aff t er A
After successful implementation of these projects, projects, the reaction batch cycle time has got reduced by 5 minutes per reaction and the batch evaporation cycle time has got reduced by 25 minutes per batch, resulting in decreased plant operating days from 28.08 days to 26.75 days.
Average power consumption/month before implementation: implementation: 625902 KWHr
Average power consumption/month after implementation implementation : 599808 KWHr
Reduction in Specific Power consumption 58 KWHr/TPE (4% reduction)
Power savings savin gs achie achi eved:
Power savings achieved per year Cost savings achieved per year
: 3.13 Lac units : 14.09 RL
Innova nnovative tive proje project ct – 1 Reduc ducing ing the Pla Plant nt opera operatin ting g da d ays by opt optimi imizzing the cycle cyc le tim time e of Batch ope op era ratio tions. ns. Aff t er A
After successful implementation of these projects, projects, the reaction batch cycle time has got reduced by 5 minutes per reaction and the batch evaporation cycle time has got reduced by 25 minutes per batch, resulting in decreased plant operating days from 28.08 days to 26.75 days.
Average power consumption/month before implementation: implementation: 625902 KWHr
Average power consumption/month after implementation implementation : 599808 KWHr
Reduction in Specific Power consumption 58 KWHr/TPE (4% reduction)
Power savings savin gs achie achi eved: This project gave scope to
seek expansion for Capex enhancement. Presently Power savings achieved per year : 3.13 Lac units EC awaited from MoEF Cost savings achieved per year : 14.09 RL for 24% increase in production capacity
Innova nnovative tive proje project ct – 2 Reduc ducing ing the t he stea steam m consum con sumpti ption on by opti o ptimizing mizing the conve con versi rsion on of Methanol to Form orma aldehyde in Reacto ctorr by reduc re ducing ing the conce conc entr ntra atio tion n of fe f eed me m ethanol. Objective :
To reduce the excessive steam consumption in the Re-boiler of Distillation column of Formaldehyde plant by reducing the methanol % fed to Distillation column.
System :
Formaldehyde is produced by partial oxidation of methanol over silver catalyst.
Air methanol as per ratio is produced in a carburetor and passed over a silver catalyst to produce produce formaldehyde. The vapor outlet of reactor is absorbed through DM water.
Feed methanol concentration is maintained at 84% so as to have excess methanol mixture fed to the t he reactor.
The liquid mixture containing formaldehyde and unreacted methanol is distilled in Dist. Column. Methanol is recycled back to the system.
Steam consumption in Distillation column is proportional to the feed Methanol %.
Innova nnovative tive proje project ct – 2 Reduc ducing ing the t he stea steam m consum con sumpti ption on by opti o ptimizing mizing the conve con versi rsion on of Methanol to Form orma aldehyde in Reacto ctorr by reduc re ducing ing the conce conc entr ntra atio tion n of fe f eed me m ethanol. Acc t i v i t y : A
Feed Methanol concentration to Carburetor was reduced from 84% to 68% keeping air constant.
Methanol fed to reactor reduced leading to less methanol % at the outlet of reactor.
Steam consumption in Distillation column got reduced due to reduced feed Methanol %.
Innova nnovative tive proje project ct – 2 Reduc ducing ing the t he stea steam m consum con sumpti ption on by opti o ptimizing mizing the conve con versi rsion on of Methanol to Form orma aldehyde in Reacto ctorr by reduc re ducing ing the conce conc entr ntra atio tion n of fe f eed me m ethanol. Before Befor e:
Recycle methanol to carburetor @ 600 kg/hr
DM water@ 650 kg/hr
Air
Carburetor
2000 Kg/hr
Reactor
Absorber
Distillation Column 3100 Kg/hr
2000 kg/ hr Steam
84 %Methanol 1850 Kg/hr
37 % Fa product @ 2500 Kg/hr
Innova nnovative tive proje project ct – 2 Reduc ducing ing the t he stea steam m consum con sumpti ption on by opti o ptimizing mizing the conve con versi rsion on of Methanol to Form orma aldehyde in Reacto ctorr by reduc re ducing ing the conce conc entr ntra atio tion n of fe f eed me m ethanol. Aff t er : A
Air
Carburetor
Recycle methanol to carburetor @ 500 kg/hr
DM water@ 500 kg/hr
Reactor
Absorber
Distillation Column
3000 Kg/hr
2000 Kg/hr
1800 kg/ hr Steam
68 %Methanol
2000 Kg/hr
37 % Fa product @ 2500 Kg/hr
Innova nnovative tive proje project ct – 2 Reduc ducing ing the t he stea steam m consum con sumpti ption on by opti o ptimizing mizing the conve con versi rsion on of Methanol to Form orma aldehyde in Reacto ctorr by reduc re ducing ing the conce conc entr ntra atio tion n of fe f eed me m ethanol. Ad A d v an antt ag ages es… … Before
After
1
Methanol Feed concentration
84%
68%
2
Reactor conversion efficiency
60%
70%
3
Unreacted Methanol fed to Distillation column
19%
13%
4
Ste Steam to Distil tillatio tion Column Re-boiler
2000 Kg/hr
1800 Kg/hr
Innova nnovative tive proje project ct – 3 Reduc ducing ing the wate waterr ingr i ngre ess int into o the th e pro proce cess ss by by aut utom oma atition on of Crude Crud e Belt Fil Filter ter cake cake wash wash.. Objective:
To eliminate the fluctuations in CAC wash water fed to Crude vacuum belt filter (CBF) by automation of wash system.
Sys ystem tem :
Crystallized Pentaerythritol (PE) along with Sodium formate (SF) in dissolved state is fed continuously to a vacuum belt filter to separate the PE as cake and SF as mother liquor.
The rate of CAC wash determines the purity of PE cake (free from SF contamination).
CAC wash rate is controlled manually by monitoring the t he flow through Rotameter.
Innova nnovative tive proje project ct – 3 Reduc ducing ing the water water ingress into int o the process by auto utomation mation of Crud rude e Belt Belt Fililter ter cake wash wash..
CAC Wash Wash Header H eader
Before :
Rotameter
Recy Recycl cled ed wash wash Feed to CBF
S 170
Feed Tank T 119
T17 02
ML
P 170-1
P 170-2
PE cake T 171 T17 03
P 170-3
Spent wash liquor to Evaporator
Innova nnovative tive proje project ct – 3 Reduc ducing ing the wate waterr ingr i ngre ess int into o the th e pro proce cess ss by by aut utom oma atition on of Crude Crud e Belt Fil Filter ter cake cake wash wash..
Con onst straints raints faced: faced:
CAC wash elsewhere in certain batch operation in the plant leads to pressure fluctuations in the CAC header leading to flow fluctuations in CBF. Additional wash requires additional Re-evaporation. Production capability reduction.
Innova nnovative tive proje project ct – 3 Reduc ducing ing the water water ingress into int o the process by auto utomation mation of Crud rude e Belt Belt Fililter ter cake wash wash.. CAC Wash Wash Header FIC
After :
Recy Recycl cled ed Wash Wash MF
Feed to CBF
S 170
Feed Tank T 119
T17 02
ML
P 170-1
P 170-2
PE cake T 171 T17 03
P 170-3
Spent wash liquor to Evaporator
Innova nnovative tive proje project ct – 3 Reduc ducing ing the wate waterr ingr i ngre ess int into o the th e pro proce cess ss by by aut utom oma atition on of Crude Crud e Belt Fil Filter ter cake cake wash wash.. Before
After
1
Average CAC wash rate.
12 lpm
10 lpm
2
Steam co consumption fo for
720 Kg/hr
600 kg/hr
Re-evaporation
Ad A d v an antt ag ages es::
Steam savings to the tune of 968 Tons/annum
Consistent cake purity leading to better process stability. stability.
Production capability increased by 1.3%
ENVIRONMEN ENVIR ONMENTA TAL L IMPRO IMPROVEMEN VEMENT T PROJECTS PROJ ECTS
Installed Methanol and Formaldehyde storage tanks vent collection and recycling system at a cost of 11.7 RL to eliminate VOC emissions thro throug ugh h tank tank brea breath thin ing. g.
Installed a over head spray nozzles in the ash yard to ensure complete suppression of dust at a cost of 4.5 RL. This is in light of the recent CPCB’s recommendations of PM 2.5
Installation of Sophisticated Dust Collecting System to keep the Boiler stack emission SPM levels to less than 50 mg/Nm3.
ENVIRONMEN ENVIR ONMENTA TAL L IMPRO IMPROVEMEN VEMENT T PROJECTS PROJ ECTS We have installed a RO system followed by MEE and ATFD to become a Zero liquid discharge unit with respect to liquid effluent. We recycle recycle almost 90% of the effluent generated. Project cost: 1.3 Cr We have implemented LDAR system to track fugitive and point source emissions. Project cost: 4.2 RL Installation of Rupture disc at upstream of Acetaldehyde bullet safety valves. Project cost: 4.3 RL
We have developed Green Belt over more than 45% of the total factory area.
ENVIRONMENTAL IMPROVEMENT PROJECTS
We have replaced the asbestos top roofs of our coal yard and boiler areas which were got damaged during Thane cyclone with environment friendly Powder coated metal sheets.
Before
After
Contd Cont d...
ENVIRONMEN ENVIR ONMENTA TAL L IMPRO IMPROVEMEN VEMENT T PROJECTS PROJ ECTS
Online VOC meters were procured for monitoring the presence of VOC in process stacks and Ejectors. Portable VOC analyzer was purchased. LDAR study was done internally and by external laboratories like M/s. SGS lab, Chennai. VOC emissions are on lower side. We have installed the Weather monitoring station in our plant and the parameters are being monitored on continuous basis.
RAIN RA IN WATER WATER HARVESTING HA RVESTING AT SITE
Tree plantation
B y o u r Ch ai r m an
B y ISO A u d i t o r s
By DEE, TNPCB TNPCB
By Employee mpl oyeess
ENERGY MONITORING FORMAT & METHODOLOGY THERMAL THE RMAL ENER ENERGY GY :
Total Steam flow from the boiler to the plant is measured using “Pressure & Temperature Compensated” Vortex tex Steam Flow meter ter.
Steam flow measurement systems are available for measuring individual flow to various sections of the plant.
Steam balance is carried out on daily basis and any increase / decrease in steam consumption vis – a – vis production is adequately reas reason oned ed out. out.
Yearly steam audit by external competent agency
Steam trap monitoring by external agency
COGEN PLANT EFFICIENCY
Efficiency is calculated on daily basis by direct method. Belt Weighment scale is fixed in the feed belt conveyor & used for meas measur urin ing g fuel fuel quan quanti tity ty.. Boiler energy audit is carried out once in a year by expert consultants. 90 to 95% of hot condensate is returned to boiler.
Al A l l c r i t i c al p aram ar amet eter erss o f t h e c apt ap t i v e p l ant an t are ar e c o n n ect ec t ed o n l i n e t o Manage nagers/ rs/E Executi xecutive vess for effective ffective monitor monitoring ing throug through h interne internet. t.
ELECT EL ECTRIC RICA A L ENE ENERGY RGY
Electrical power tree is prepared to monitor fixed and variable power consumption.
KWhr consumption is monitored for overall plant and individual sections and the consumption is compared with production and any variatio tion is reasoned out.
Equipment running hours are monitored on daily basis to identify idle running/under loading of the machineries
Utility report is generated on daily basis which captures specific power, steam and water ter consumption.
Any deviation of the specific consumption figures from the “Budget” is captured in terms of LOSS/GAIN in Rupees on daily basis.
MODEL ENERGY MONITORING MONITORING FORMAT
MODEL ENERGY MONITORING MONITORING FORMAT Daily Power Power consump cons umptio tion n report Monthl onthlyy Power Power consumpt con sumption ion re report port
IMPLEMENT IMPL EMENTA A TION OF SUGGESTIONS SUGGESTIONS
Energy week is celebrated in the month of December to emphasize the importance of energy conservation across the factory.
Energy conservation related ideas received from employees through suggestion scheme is evaluated, ideas worth implementing are rewarded with “Energy with “Energy Efficient Gadgets” Total No
no of suggestio suggestions ns received received in 11-12 11-12
of sugges suggestio tions ns implem implement ented ed
- 22 - 17
On completion of the project, IRR projected and IRR actually realized is compared.
To improve the awareness on Energy conservation, CFL lamps issued to all daily contact workmen during the safety week celebrations March’2012.
IMPLEMENT IMPL EMENTA A TION OF SUGGESTIONS SUGGESTIONS
Replacement of 150W SV lamps with 45 W LED street light fittings.
Before
Aff t er A
RENEWAB REN EWABL L E ENERGY ENERGY PROJECTS PROJECTS
Installed Natural draft air ventilators on top of Stores, Workshop and Boiler, investment made RL 1.55 and Savings RL 1.7/annum 1.7/ annum due to stoppage of power driven exhaust fans. Extending the same facility to Coal storage sheds this year.
5% of entire plant roof is converted into transparent PVC sheets, thereby achieving saving of 0.4RL/annum in lighting system.
As an alternate to the coal, we also use Rice husk as a co-fuel co-fuel in the Boiler.
Contd Cont d...
RENEWAB REN EWABL L E ENERGY ENERGY PROJECTS PROJECTS
Solar Water heating system to Industrial Dish Washing application in canteen at a cost of RL 2.2, thereby achieving achieving saving of 1.18 RL/annum.
ENCON eff ffor orts ts fo forr futu fu ture… re…
Reduction of throttling losses across TG by Modification of Nozzle plates. Reducing the head pressure of Boiler De-aerator feed water pumps. Ins Installation ion of VFD for for Ins Instrument Air compressor. Pow Power conservation by efflu fluent reduction ion at source. Reducing the surface moisture of coal by installing Turbo ventilators in Coal storage sheds. Replacement of worm gear with inline helical gear for ETP aerator. Replacement of pneumatic level instru truments with Ele Electronic typ type. Ins Install tallat atio ion n of Ener Energy gy Moni Monito tori rin ng Sys System. tem. Optimizing the power consumptions of Vacuum pump in Crude Belt Filter. Replacement of conventional Light fittings with LED fittings and Light pipe. Ins Instal tallatio tion of solar systems for for lighting requirements. ts. Continuing with phase wise replacement of standard motors with EFF1 EFF1 moto motors rs.. Encourage employees to qualify as Certified Energy Manager/Auditor.
Best Be st practices on ene nergy rgy front fron t imp imple leme mented nted thro through ugh our asso ssociate ciatess
Persuaded the coal suppliers to shift importing of coal from f rom Chennai to a nearby port at Karaikal to reduce transportation distance by 200 KM per trip of truck…. Reduction in Diesel consumption by the trucks. t rucks.
While evaluating the quality of imported coal, special weight age is given for ash and and sulph su lphur ur content though they do not contribute to the ‘heat value’ of the coal. This is based on the environment impact on account of high ash and high sulphur coal usage.
Increased the Acetaldehyde tanker capacity from 8MT to 16MT to reduce the number of trips of tanker….Truck movement on this RM supply has reduced by half.
We have implemented a system for the vehicles used for other plant works to be completed locally with a predefined schedule thus avoiding frequent vehicle movement.
IMPLEMENTATION OF CORRECTIVE / PREVENTIVE ACTIONS FROM ISO 14001 / OHSAS 18001 CERTIFICATION
Date of audit: 27.02.2012 Sl. Sl . No
Standard
Descrip Description tion and Consequence
Category Category of of Finding
Corrective actions
Preventive Act A ctii o n
1
ISO 14001:2004
Requirement: ISO 14001:2004 Cl.4.5.3 states that "Actions taken shall be appropriate to the magnitude of the problems and the environmental impacts encountered. The organization shall ensure that any necessary changes are made to environmental management system documentation" Failure: Investigation has not been done for some environment related Non-conformance reported during the recent cyclone. Evidence: The evidences are Physically verified for some location.
Minor/ 4.5.3
EIA impact study will be completed for chemical spillages and damages in hazardous material storage area and scarp yard.
Corrective actions arrived at will be implemented. This aspect has been incorporated in the procedure manual.
2
ISO 14001:2004 / OHSAS 18001
Operational Controls to be improved in the following area in the Pentaerythritol Production Main Control Control Room (MCR):(MCR):- Noise Noise emanating from the MCR AC Compressor is on the higher side. Noise level monitoring to be done here since this Compressor is
Observation/
AC compressor compressor area will be included in the Noise survey monitoring area and periodic monitoring of Noise will be
Effectiveness is being ensured during internal monthly EHS meeting.
4.4.6
Aw A w ar ard d s an and d Rec Reco o g n i t i o n s ….
We have won "The Environmental Best practices Award” for “Most Innovative Environmental project” by CII in Jan’2011
Cha halllle enges face faced d durin du ring g “ THAN ANE E” cyc cyclon lone e
Our plant got devastated during Thane cyclone on 30th Dec 2011 With concentrated team efforts we overcame the challenges and restored the plant to achieve the targeted production.
Before Cycl Cyclone one
Af A f t er r est es t o r ati at i o n
EXISTENCE OF HUMAN RACE IS CENTERED AROUND “ENERGY” ENERGY IS THE “BREATH” OF INDUSTRY.
IT CAN NEITHER BE CREATED NOR DESTROYED. BUT CAN BE “CONSERVED” .
THA NK YOU !! !!!
