68

First Prize

Chlor-Alkali

ADITYA BIRLA CHEMICALS (INDIA) LTD.

(CHEMICAL DIVISION)

Renukoot (Uttar Pradesh)

Unit Profile

Aditya Birla Chemicals (India) Limited, Renukoot Chemical Division, formerly known

as Kanoria Chemical Industries Limited (KCIL). KCIL stated its production with

Mercury based technology in year 1964. The plant capacity was enhanced in year

2006 and 2008 with installation of 110 TPD each.

The products of the unit are Caustic Soda Lye, Liquid Chlorine, Hydrochloric Acid,

Stable Bleaching Powder, Aluminium Chloride, Poly Aluminium Chloride, and

Chlorinated Paraffin.

Energy Consumption

Item description Unit 2012 – 13 2013 – 14

Electrical Energy kWh/T 2626 2466

Thermal Energy M kCal/T 1.26 1.03

Total Energy Bill Rs Lakh 14219.9 19462

Energy as % of total cost % 62 61

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Energy Conservation Measures Taken

1. Reduction in operating Current Density

In year 2012-13 decision was taken to

replace 120 elements of Generation “IV” with

generation “V-B” at facility Mem-I. In year

2013-14 spare Generation “IV” membrane

realigned in all the three facility. Without

change in production capacity of 365 TPD,

current density at all the three plants were

rationalised which resulted sustained

reduction in the specific Consumption of all

three units.

Investment : Nil

Electricity savings : 155.50 Lakh kWh/Annum

Money saving (including Coal) : Rs. 1,351 Lakh/Annum

2. Energy Consumption at cooling tower

Existing cooling water pumps were replaced by energy efficient pumps with IE-III

motor.

Investment : Rs 16.0 Lakh

Electricity savings : 20.04 Lakh kWh/Annum

Money saving (including Coal) : Rs. 174.24 Lakh/Annum

3. Energy reduction at Chlorine Compression

It was observed that installed chlorine compressors were with higher capacity and

lot energy is getting wasted through recirculation. The optimum utilisation of

Chlorine compressors were achieved by

Facility Previous Current

Mem-I Fixed speed Motor VFD driven Motor with modified SOP

Mem-II VFD running at full speed SOP altered to gain benefits through

altering compressor speed.

Mem-III Operating with Lower

suction pressure and lower

capacity utilization.

SOP altered to operate with higher

suction pressure and better capacity

utilization.

Investment : Rs. 8.2 Lakh

Electricity savings : 8.19 Lakh kWh/Annum

Money saving (including Coal) : Rs. 74.75 Lakh/Annum

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4. Chilled water Pump at Mem –III

Energy consumption at chilled water pumping was

reduced after revisiting chilled water flow and head

demand. Spare pump within the facility is now being

utilised to meet the chilled water demand.

Previous : 215 m3/hr, 48 m head, 45 kW.

Current : 200 m3/hr, 30 m head, 30 kW.

Investment : Nil

Electricity savings : 1.20 Lakh kWh/Annum

Money saving (including Coal) : Rs. 10.56 Lakh/Annum

5. Brine Integration

Initially all the three manufacturing facilities had their own primary brine

preparation system. Revisiting equipment design (operating capacity), process

inefficiency and operating procedures an integrated primary brine preparation were

achieved. This resulted in stoppage many process equipments and significant

reduction in auxiliary consumption. The benefits don’t include gain achieved through

temperature and cell power reduction.

Investment : Nil

Electricity savings : 7.16 Lakh kWh/Annum

Money saving (including Coal) : Rs. 62.24 Lakh/Annum

6. Compressed Air System integration

Air to plant was compressed using three smaller sized air compressors. A study was

performed to evaluate overall plant air consumption, and concluded that air demand

could be catered by a single compressor (with standby) lying unutilized which was

procured with latest facility. This also called for replacing air operated pumps with

motor coupled pump. Major overhauling of compressors were done to ensure

mechanical integrity and taken in line.

Investment : Nil

Electricity savings : 8.34 Lakh kWh/Annum

Money saving (including Coal) : Rs. 72.51 Lakh/Annum