09 a Kalyanasundaram Thirumalai
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Transcript of 09 a Kalyanasundaram Thirumalai
Thirumalai Chemicals Ltd.,RanipetThirumalai Chemicals Ltd.,Thirumalai Chemicals Ltd.,RanipetRanipet
1
Thirumalai Chemicals LtdRanipet, India
History of Thirumalai Chemicals Limited ……
Public limited Company
Started in the Year 1973
Sales Turnover Rs.400 crores
Global Leader for all products
TCL – India & TCL – Malaysia together has the largest capacity in the
world to produce Maleic Anhydride
Our products & Applications
Phthalic Anhydride – 87, 000 Tons / Year
Paints
Polyester Resins
Plasticizers
Maleic Anhydride – 17, 750 Tons / Year
Paints
Pharmaceuticals
Polyester Resins
Malic AcidFood Acids – 17, 000 Tons/Year
Soft Drinks
Candies
Pharmaceuticals
For Manufacturing Cheese
Fumaric AcidFood Acids – 17, 000 Tons/Year
Candies
Soft Drinks
Animal Feed
1973
1997-98
PA 6000 TPA
PA 19,000 TPA
PA 25,000 TPA
PAN 87,000 TPA
1974-76
1985-86
1988-89
1997-98
MA 1,000 TPA
MA 11,000 TPA
MA 17,750 TPA
1988-89
1990-91
FOOD ACIDS 1,000 TPA
1991-92
FOOD ACIDS 17,000 TPA
1997-98
Organizational Growth
ISO 9002
INEA
INEA – International Export Award
ISO 14001:1996
ISO 9001:2
000
ICMA Energy Award
HACCP
ISI Fumaric
Acid
ISO 14001: 2004
AWARDS AND MILESTONES…
1994
1995
2000
2001
2002
2003
2004
2006
Importance of Energy Management in TCL
Importance of Energy Management in TCL
TCL, being a Petro chemical Industry, is energy Intensive.
Energy cost contributes to about 3-4 % of the manufacturing costs and is next to raw material cost.
The increased competition and raising prices of Power & Fuel demands cost reduction in all respects for survival.
The prime focus is on Energy cost reduction through efficient waste heat recovery, conservation measures and productivity improvement.
The main emphasis is towards Generation, Distribution and Usage of Steam & Power as efficiently as possible.
Establishment of Energy Cell in TCL
Opportunities to implement energy conservation activities.
Formed a separate energy cell in the Year 2000.
Energy Cell comprises of an Energy Manager & Energy Engineer.
Activities of Energy Cell in TCL
Energy Cell’s main role is to Facilitate Energy Conservation activities to optimize Energy ConsumptionActivities:1. Data collection:
a. Steam generation & consumption
b. Power generation & consumption
c. Fuel consumption 2. Preparation of Steam & Power balance for entire network
3. Calculation of daily energy cost through a separate Energy Module for various products
4. Efficiency calculations of high energy generating equipments like Turbines, Turbo blowers & fired heaters.
Activities of Energy Cell in TCL Contd…
5. Analyzing & taking immediate Corrective actions for daily deviations
6. Monitoring of instrument air generation & consumption
7. Maintaining records for daily deviation to eliminate for future occurrences
8. Calculating daily losses (venting & failure losses)
ENCON Methodology
ENCON Methodology
Idea Generation
Audit &Monitoring
ImplementationFeasibilityStudy
From Energy Cell
From HODs,
Engineers &Supervisors
From TPM circles
Through Suggestions
By HODs or energy cell
Preparation of detailed report
( Investment, cost,benefit ,Payback etc)
Approvalby
Management
Implementation by
Concerned HODs
Report Generation after Completion
Audit by Energy cell
Report Generation On Actual saving & Expected Saving
Monthly Monitoringthe Performance
by Energy cell
Energy Conservation Activities Carried out
in Electrical Systems
1.Stoppage of unnecessary & Idle running drives
2. Conservation using V.F.D.
3. Power Reduction using Pulley Changing.
4. Capacitor provision to improve power factor
5. Frequency reduction in the generating point
6. Voltage Reduction in Feeder from 500V to 415V
7. Segregation of Low & High Head Cooling Water Pumps.
8. Installing Energy Efficiency Motor.
9. Energy efficient lamps
10. Providing LED Lamps for Panel Indication.
Energy Conservation Activities
Variable frequency drive - Speed Reduction
Downsizing the motors - Lower Capacity motor
Pulley size changing - Speed reduction of Drives
Energy Conservation in Cooling Water System
Various Power Reduction Activities
Case Study –
Energy conservation in Hot Oil Circulation Pump using VFD
I - VFD Installation in Hot Oil Pump (PA Plant)Before Condition:
∗ During re-cooling, hot oil is re-circulated bypassing SWC. Hence scope for Power reduction.
SWC-1 SWC-2 SWC-3 SWC-4 SWC-5
HOT OIL TANK
HOT OIL SYSTEM
Running amps : 24 ampsRunning Power : 17.0 KwFrequency : 50 Hertz
After Condition:∗ Power reduction can be achieved by reducing the speed by reducing the
frequency.
∗ Interlocked with the recycle valve.
∗ The flow at the reduced speed is sufficient to maintain the
hot oil temperature.
SWC-1 SWC-2 SWC-3 SWC-4 SWC-5
HOT OIL TANK
Running amps : 7.5 ampsRunning Power : 5.0 KwFrequency : 30 Hertz
VFD
MELTING CYCLE RECOOLING CYCLE
Running amps : 7.5 amps
Running Power : 5.0 Kw
Frequency : 30 Hertz
Power Savings : 12 KwHR = 0.288 Lakh kwh/Annum
RESULT
Running amps : 24 amps
Running Power : 17.0 Kw
Frequency : 50 Hertz
Energy management
Case Study
Elimination of Power Lossin MA plant
BEFORE
1440 RPM
37 KW
30-40 %
Oxidation temperedwater pump
Suction line
Speed 1440 rpm
Motor 37 KW
Discharge valve opening 30%-40%
AFTER
960 RPM
18.5 KW
70-80 %
Oxidation temperedwater pump
Suction line
Using VFD RPM reduced to 960
Satisfies the process requirements
Motor changed to 960 RPM
COST BENEFIT
Project costRs 0.5 Lakhs Saving / month
Rs 0.8 Lakhs
Pay back 20 days
Energy management
Case Study
Power Reduction in Blowers
(FUMARIC ACID PLANT)
AIR EXHAUST TO FINES RECOVERY SYSTEM
PREHEATING ZONE HEATING ZONE COOLING ZONE
15 BAR STEAM
AIR PREHEATER
DRYER BLOWER
COLD AIR DUCT
HOT AIR DUCT
PIN AGITATOR
WET MATERIAL INLET
AGITATOR
FUMARIC BED
150 deg C
Process of Fumaric Acid Drying
HIGHER CAPACITY OF BLOWER SPEED-1440 RPMDamper opening 30%
DAMPER
30 %OPEN
DRIER
PULLEY 310 mm
1440 rpm
BEFORE
DAMPER OPENING INCREASED TO 70% BY REDUCING THE SPEED TO 920 RPM BY CHANGING THE PULLEY SIZE TO 400 MM
DAMPER
70 %OPEN
DRIER
PULLEY 400 mm920 rpm
AFTER
Pulley (400 mm)
Blower
Motor
RESULTS
28
13
10
15
20
25
30
BEFORE AFTER
KW/hr
REDUCTION IN POWER CONSUMPTION
Good
BENEFIT
0
3.9
0
1
2
3
4
BEFORE AFTER
Lakhs/ Annum
GOOD
ROI
INVESTMENTRs. 0.05 LAKHS BENEFIT
Rs. 3.9 LAKHS
ENERGY MANAGEMENT
Case Study –
Energy conservation in Cooling water system
ANALYSIS
Three High capacity ( 90 kW ) Cooling water pumps are in operation for serving Two Turbo Blowers & one Turbine generator.
During Part load operation ( One TG & One Turbo blower ) all three high capacity pumps has to run.
No Low capacity pumps is available to satisfy part load operation
System studied and provided one low capacity 55 kW cooling water Pump.
High Power consumption in Utility cooling water system during part load
operation
BACKGROUND
KAIZENS
50 % OPEN
90 kW
90 kW
90 kW
To Turbo Blowers & Turbine
FULL OPEN
55kW
90 kW
To Turbo Blowers & Turbine
Before After
RESULTS
Power Consumption kW / hr
215
250
200
220
240
260
280
BEFORE AFTER
BENEFIT
0
15.12
0
2
4
6
8
10
12
14
16
BEFORE AFTER
Saving RS in lakhs / Year
Energy Conservation Activities Carried out
in Thermal Systems
Implementation of Co-Generation System
Introducing new Flash Drums
Insulation of Chimney- To Reduce Flue Gas Temperature from 220*C to 200*C
Increasing Productivity thereby increasing Steam Generation
Steam Trap Performance Checking using Ultra Probe-2000
Process Modification in Distillation Batches- Reduction in Steam Consumption
Optimizing Air PreHeater Steam Consumption.
Steam Leak Arresting using a separate Team
Energy Conservation Activities
Energy management
Case Study
Implementation of Co-Generation System
Co-generation system in TCL
Consumers
40 Bar(HPS)
40 Bar (HPSH)
15 Bar(MPSH)
Turbine
15 Bar (MPS)
DSH
Turbo Blowers
6 Bar Steam
4 Bar Steam
Consumers
Condensate
Superheater
6 Bar Flash Drum
4 Bar Flash Drum
Boiler feedwater Tank
Condensate
Condensate
4 Bar from DistillationCondenser
Contd…
Heat Recovery Unit of Reactors
Our processes are designed to utilise all heat liberated from exothermic reaction
Generation of high pressure steam (40 bar)
Meets both Process heating & Power requirements
Our process requires steam at various Pressures.
Installed a 5 MW Turbo generator (Extraction cum Condensing )
The extraction steam meets process requirements.
Co-generation system Contd…
Best Practices in Co-generation systemContd…
Generation of 4 bar steam from distillation condenser
Recovery of 4 bar steam from Medium pressure condensate, through flash drum
4 bar steam is used for process heating
All the steam condensate after heat recovery is diverted to Boiler feed water tank in order to utilize the sensible heat.
Steam driven Turbo blowers meet our process air requirement Medium pressure flash drums in condensate network, to recover
. steam at 6 bar.
Implementation of New HP Flash Drum
Case Study
Energy conservation in Steam Network
BACKGROUND
Generation of 4bar Steam from 40bar,15 bar condensates.
Generation of 4 bar steam is in excess.
Venting of 4 bar steam.
ANALYSIS
In normal Plant operation,venting of 4 bar is resulted.
During the shutdown period of downstream plants,venting of 4bar steam is high.
6 bar demand for plant heating is met by letting down from 15bar to 6 bar .
So it is planned to flash 40,15bar condensates into a new Medium pressure flash drum to generate 6 bar steam.
4 Bar steam
Condensate
Condensate
6 BarFlash
Vessel
6 Bar steam
High PressureCondensate
Before:4 Bar Steam Vented to Atmosphere
After:6 Bar Flash Drum Introduced
Flash Vessel
High Pressure Condensate
Low Pressure Condensate
4 BarFlash Vessel
Low Pressure Condensate
4 Bar steam
Condensate
RESULTS• Venting of 4 bar steam is minimized
• Cost Saving is Rs.3.5lakhs/month.
• Horizontal Implementation in another Plant.
S a v in gR s 3 .5 L a k h s
I n v e s tm e n tR s 1 .0 0 L a k h s
BENEFIT
Extent of Team Work in ENCON Activities
Identifying / eliminating energy related abnormalities through O&M
Concept
Monitoring & taking corrective actions through Daily Work management
Concept of Small group activities has given a clear approach & idea on
loss elimination techniques
Most of the abnormalities like steam leaks,Instrument air leaks,
Condensate leaks are attended by Operators themselves
Contribution of Workmen / Supervisors
Steam traps inspection & skin temperature measurements are being carried
out by respective plant supervisors
Energy week & Suggestion scheme motivates our employees to give
innovative & creative suggestions
Every employee is involved in one or other of the energy conservation
activities implemented in his plant which gives them a sense of
accomplishment
Contribution of Workmen / Supervisors Contd..
Overall Results
2.00
1.46
1.101.01
1.16
0.63
0.00
1.00
2.00
3.00
2000-01 2001-02 2002-03 2003-04 2004-05 2005-06
MILLION K.cals / MTSpecific Energy Consumption
in Million K.cals / MT of Product
163.6
124.7
100.092
103
56
0
20
40
60
80
100
120
140
160
180
2000 -01 2001 -02 2002 -03 2003-04 2004-05 2005-06
LTS/ MT
Specific F.O Consumption (Lit/MT)
36.2
23.0
9
13
6
12.6
0
5
10
15
20
25
30
35
40
2000 -01 2001 -02 2002 -03 2003-04 2004-05 2005-06
LTS/ MT
Specific H.S.D Consumption (Lit/MT)
27
35
26
12
26
63
0
10
20
30
40
50
60
70
2000 -01 2001 -02 2002 -03 2003-04 2004-05 2005-06
KW/ MTSpecific Consumption - EB
12.7
11.411.6
10.9
8.6
6
7
8
9
10
11
12
13
14
2001-02 2002-2003 2003-2004 2004-2005 2005-2006
(KL/MT)
Specific Water Consumption (KL/MT)
Future Improvements
To eliminate 4 bar venting (excess) steam, Planned to install a new
boiler feed water preheater
Horizontal Implementation of High & Low Head Cooling Water
Segregation in another Plant.
Installation of new SBC to increase the productivity
Replacement of Electric heater with Steam heater in the Air
drier unit
Thank you