asian paints limited penta division cuddalore
DESCRIPTION
penta division asian paintsTRANSCRIPT
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EXCELLENCE IN ENERGY MANAGEMENT
BY
ASIAN PAINTS LTD.PENTA DIVISION, CUDDALORE.
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ABOUT US …
Asian Paints is India’s largest Paint Company and ranked amongthe Top 10 decorative coating companies in the World.
We have 28 Manufacturing facilities across the World servicingConsumers in 65 Countries.
In India, we have 9 plants manufacturing coatings and 2 plantsmanufacturing chemicals. Our Unit manufacturing Pentaerythritol is located at Cuddalore, Tamilnadu.
Penta Division is accredited with ISO 14001 and OHSAS 18001certification and manufacturers following chemicals :
Various grades of PentaerythritolSodium FormateFormaldehyde
We have an enviable reputation for innovative Energy conservationpractices which helped us to bring down the specific energyconsumption, helping the division survive.
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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.
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Reaction
Crystalliser
Pure Vacuum Crystallizer
Tech Dissolver
TO AIR
PE : Pentaerythritol
Ca
FaAa
Distillation Column
For Formaldehyde and Methanol Recovery
Sodium Formate Drier
Sodium Formate Bagging
TO AIR
Crystalliser Mech Sieving
PROCESS BLOCK DIAGRAM
Knock Down Tank
Stripper Five Effect Evaporator
Crude Vacuum Crystalliser
Crude Belt Filter
Deionizer / Carbon columns
Tech PE Drier
TO AIR
Tech PE Bagging
Tech PE Silo
Mono PE Drier
TO AIR
Mono PE Bagging
Mono PE Silo
Di PE Bagging
Crude Mother Liquor
Di PE Drier
Di PESilo
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ENERGY COSTING
The Co-Gen system generatesrequired Electrical energy.Cost of imported Energy fromthe grid alone is captured asElectrical energy cost.
75.6
24.4
94.1
5.9
95.2
4.8
0
20
40
60
80
100
2009-10 2010-11 2011-12
Electrical Energy CostThermal Energy Cost
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
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Sl.No.
Activity (2009-10) 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)
Cost Saving Per annum
(RL) Saving as % of energy bill
1. Replacing Crude Belt Filter (CBF) Vacuum pump with Energy efficient pump
1.1 --- 15.4 0.73 --- 3.27
0.41 %
2. Replacing Pure Belt Filter (PBF) Vacuum pump with Energy efficient pump
0.96 --- 13.7 0.65 --- 2.9
0.37 %
3. 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 for the same Steam flow.
749 --- --- 36.29 --- 163.3
20.6 %
4. Reducing 1500 KVA Turbo Alternator frequency from 50 Hz to 48.5 Hz
0 --- 108.4 5.09 --- 22.93
2.9 %
Contd . . .
ENERGY CONSERVATION ACTIVITIES 2009 to 2012
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S.No Activity (2009-10) 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)
Cost Saving Per annum
(RL) Saving as % of energy bill
5. Increasing the 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 --- 10.29 0.48 --- 2.18
2.7 %
6. 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 --- --- 13.55 --- 60.96
7.67 %
7. Firing of Waste gas containing Hydrogen and traces of methanol from Formaldehyde plant in boiler for generating steam
1.6 --- --- --- 961 45.17
5.69 %
8. Installation of 2Nos of 18.5 KW VFD for Cooling Tower Fan application.
1.6 --- 15.44 0.73 --- 3.99
0.5 %Contd . . .
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Sl.No
Activity (2010-11) Invest-ment (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)
Cost Saving Per annum
(RL) Saving as % of energy bill
9. 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.
3.75 0.037 19.4 1.05 32.63 6.29
0.68 %
10. Optimization of Batch cycle time in Vacuum Crystallizer by Removing the Cyclone separator which was a part of imported crystallizer.
0 0.202 --- --- 176.8 8.48
0.92 %
11. Increasing the Power throughput 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 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 --- --- 3.33 5.8 14.97
1.63 %
Contd . . .
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Sl.No
Activity (2010-11) 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)
Cost Saving Per annum
(RL) Saving as % of energy bill
12. Replacing 150 W, HPSV Street light fittings with LED fittings of 30W (10 Nos)
0.95 --- 1.05 0.06 --- 0.26
0.03%
13. Replacing Electric storage Water heaters with Solar water heater in canteen application.
2.2 --- 4.87 0.26 --- 1.18
0.13 %
14. Installation of a Boiler steam 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 --- --- --- 552 28.69
3.1 %
Contd . . .
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Sl.No
Activity (2011-12) 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)
Cost Saving Per annum
(RL) Saving as % of energy bill
15 Reducing the plant operation 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. Reducing the batch cycle time of T148 (Tech dissolver) by 15 min. by simultaneous pumping of its feed streams.
0.0 --- 57.99 3.13 14.09
1.4 %
16 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 0.299 --- -- 261.1 13.86
1.4 %
17 Reducing the water ingress into the process by automation of Crude Belt Filter cake wash.
0.9 0.179 --- --- 155.64 8.32
0.83 %
Contd . . .
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Sl.No
Activity (2011-12) 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)
Cost Saving Per annum
(RL) Saving as % of energy bill
18 Reducing Power consumption of Lobe blower for conveying Off gas from Formaldehyde plant to Boiler by reducing the pressure drop across the line.
2.75 -- 16.43 0.89 -- 3.99
0.4 %
19 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 --- --- 1.51 --- 6.8
0.69 %
20 Reducing the Power consumption in ETP aerator by providing VFD with necessary speed control system based on COD level in aerator.
0.9 --- 4.87 0.26 --- 1.18
0.12 %
21 Replacing 150 W, HPSV Street light fittings with LED fittings of 45W (10 Nos)
0.99 --- 0.93 0.05 --- 0.23
0.02 %
Other miscellaneous projects over the past three years (14 projects)
8.76 5.13 108.2 39.143.86%
TOTAL 789.6
29.2 %77.49 2062 460.8
17%
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Sl.No
Activity (2011-12) 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)
Cost Saving Per annum
(RL) Saving as % of energy bill
18 Reducing Power consumption of Lobe blower for conveying Off gas from Formaldehyde plant to Boiler by reducing the pressure drop across the line.
2.75 -- 16.43 0.89 -- 3.99
0.4 %
19 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 --- --- 1.51 --- 6.8
0.69 %
20 Reducing the Power consumption in ETP aerator by providing VFD with necessary speed control system based on COD level in aerator.
0.9 --- 4.87 0.26 --- 1.18
0.12 %
21 Replacing 150 W, HPSV Street light fittings with LED fittings of 45W (10 Nos)
0.99 --- 0.93 0.05 --- 0.23
0.02 %
Other miscellaneous projects over the past three years (14 Nos.)
8.76 5.13 108.2 39.143.86%
TOTAL 789.6
29.2 %77.49 2062 460.8
17%
IRR 28.1%
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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 by the Technology provider M/s.Hercules Inc.,USA.
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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
19.56 1363
A whopping reduction of 22 % in Steam Consumption 48 % in Power Consumption
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TREND- SPECIFIC POWER CONSUMPTION
A whopping reduction of 52% in Power Consumption
2750
2400
2150
1825
1363
152115481554
2694
2431
15871695
2850
2643
1929
2200
2090
1489 1421 1391
154015401550
1650
2400
1550
1975
14501380
1510
1200
1400
1600
1800
2000
2200
2400
2600
2800
3000
ACTUALS 2850 2694 2643 2431 2200 2090 1929 1695 1587 1554 1548 1521 1489 1421 1391 1363
TARGETS 2750 2400 2400 2150 1975 1825 1650 1550 1550 1540 1540 1510 1450 1380
96-97 97-98 98-99 99-00 00-01 01-02 02-03 03-04 04-05 05-06 06-07 07-08 08-09 09-10 10-11 11-12
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1510
14211450
1391 13801363
1250
1300
1350
1400
1450
1500
1550
2009-10 2010-11 2011-12
TargetActual
TREND- SPECIFIC POWER CONSUMPTION
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TREND - SPECIFIC STEAM CONSUMPTION
A whopping reduction of 41.3 % in Steam Consumption
33.30
30.30
27.8027.25
25.03
23.37
21.04
19.18 19.1020.01
19.2019.2519.00 19.0819.81 19.56
29
27 27
2422.75
20.75
18.35
2120 20 20 19.5 19.8 19.6
16.00
18.00
20.00
22.00
24.00
26.00
28.00
30.00
32.00
34.00
36.00
16
18
20
22
24
26
28
30
32
34
36
ACTUALS 33.3030.30 27.80 27.25 25.0323.37 21.04 19.18 19.1020.0119.20 19.2519.00 19.0819.81 19.6
TARGETS 29 27 27 24 22.8 20.8 18.4 21 20 20 20 19.5 19.8 19.6
96-97
97-98
98-99
99-00
00-01
01-02
02-03
03-04
04-05
05-06
06-07
07-08
08-09
09-10
10-11
11-12
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19.519.05
19.8 19.81 19.6 19.56
1515.5
1616.5
1717.5
1818.5
1919.5
20
2009-10 2010-11 2011-12
TargetActual
TREND - SPECIFIC STEAM CONSUMPTION
We have commissioned a Zero liquid Discharge systemcomprising of Multiple Effect Evaporator and ATFD leading toincrease in Steam consumption.
18.8 18.6**
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Reaction
Crystalliser
Pure Vacuum Crystallizer
Tech Dissolver
TO AIR
PE : Pentaerythritol
Ca
FaAa
Distillation Column
For Formaldehyde and Methanol Recovery
Sodium Formate Drier
Sodium Formate Bagging
TO AIR
Crystalliser Mech Sieving
PROCESS BLOCK DIAGRAM
Knock Down Tank
Stripper Five Effect Evaporator
Crude Vacuum Crystalliser
Crude Belt Filter
Deionizer / Carbon columns
Tech PE Drier
TO AIR
Tech PE Bagging
Tech PE Silo
Mono PE Drier
TO AIR
Mono PE Bagging
Mono PE Silo
Di PE Bagging
Crude Mother Liquor
Di PE Drier
Di PESilo
Bottlenecks
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Innovative project – 1Reducing the Plant operating days by optimizing the
cycle time of Batch operations.
Concepts :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 manufacturing of Mono PE – the batch cycle time of Batch evaporation was optimized by which the number of batches/day was increased.
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Activity (A). Optimization of Reaction time:
Conducted Pilot reactor studies.
Sample output analyzed every 5 minutes and compared withstandards.
By increasing the rate of addition of the reactants to theReactor without affecting the kinetics of the reaction, the Reactionbatch 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, average Reactionbatches per day got increased to 18.5 from 17.5.
Innovative project – 1Reducing the Plant operating days by optimizing the
cycle time of Batch operations.
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Reactor
P‐101
Acetaldehyde
FormaldehydeCaustic
Before
Reaction Time 45 Mins
CW O/LCW I/L
CHW I/LCHW O/L
Duration in minutes
Chilled water to PHE
10
Cooling water to PHE
35
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Reactor
P‐101
After
Reaction Time 40 Mins
Duration in minutes
Chilled water to PHE
15
Cooling water to PHE
25
Acetaldehyde
FormaldehydeCaustic
CW O/LCW I/L
CHW I/LCHW O/L
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Activity (A): Optimization of Reaction Batch cycle 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
Innovative project – 1Reducing the Plant operating days by optimizing the
cycle time of Batch operations.
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Activity (B). Optimization of Batch evaporation:
By implementing the system of simultaneous pumping of two feedstreams for evaporation, the batch evaporation cycle time has gotreduced by 30 minutes per batch, because of which the number ofbatches per day has got increased.
Flow meters with integrators were installed in both feed streams inwhich the required quantity of feed were set and batch pumpingwas done in auto mode because of which the time delay due tomanual pumping of two streams one by one was eliminated completely.
Innovative project – 1Reducing the Plant operating days by optimizing the
cycle time of Batch operations.
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50%
Before
Pumping Time 30mins
Pumping Time 25mins
20%
80%
Total Filling Time 55mins
Innovative project – 1Reducing the Plant operating days by optimizing the
cycle time of Batch operations.
Tech Dissolver
Pure Penta Solution Recycled Penta Solution
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After
Total Filling Time 30 mins
Tech Dissolver
Pure Penta Solution Recycled Penta Solution
FIT FIT
20%
80%
Innovative project – 1Reducing the Plant operating days by optimizing the
cycle time of Batch operations.
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Activity (B): Optimization of Tech dissolver batch cycle time
Before After1 Feed streams pumping time 55 min 30 min
2 Tech Dissolver Batches 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
Innovative project – 1Reducing the Plant operating days by optimizing the
cycle time of Batch operations.
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After
After successful implementation of these 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: 625902 KWHrAverage power consumption/month after implementation : 599808 KWHrReduction in Specific Power consumption 58 KWHr/TPE (4% reduction)
Power savings achieved:
Power savings achieved per year : 3.13 Lac unitsCost savings achieved per year : 14.09 RL
Innovative project – 1Reducing the Plant operating days by optimizing the
cycle time of Batch operations.
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After
After successful implementation of these 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: 625902 KWHrAverage power consumption/month after implementation : 599808 KWHrReduction in Specific Power consumption 58 KWHr/TPE (4% reduction)
Power savings achieved:
Power savings achieved per year : 3.13 Lac unitsCost savings achieved per year : 14.09 RL
Innovative project – 1Reducing the Plant operating days by optimizing the
cycle time of Batch operations.
This project gave scope to seek expansion for Capex enhancement. Presently
EC awaited from MoEF for 24% increase in
production capacity
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Innovative project – 2Reducing the steam consumption by optimizing the
conversion of Methanol to Formaldehyde in Reactor by reducing the concentration of feed methanol.
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 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 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 %.
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Activity:
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 %.
Innovative project – 2Reducing the steam consumption by optimizing the
conversion of Methanol to Formaldehyde in Reactor by reducing the concentration of feed methanol.
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Air2000 kg/ hr Steam
2000 Kg/hr
Carburetor
84 %Methanol1850 Kg/hr
Reactor Absorber
DM water@ 650 kg/hr
Distillation Column
Recycle methanol to carburetor @ 600 kg/hr
37 % Fa product @ 2500 Kg/hr
3100 Kg/hr
Before :
Innovative project – 2Reducing the steam consumption by optimizing the
conversion of Methanol to Formaldehyde in Reactor by reducing the concentration of feed methanol.
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Air1800 kg/ hr Steam
2000 Kg/hr
Carburetor
68 %Methanol
Reactor Absorber
DM water@ 500 kg/hr
Distillation Column
Recycle methanol to carburetor @ 500 kg/hr
37 % Fa product @ 2500 Kg/hr
3000 Kg/hr
After :
2000 Kg/hr
Innovative project – 2Reducing the steam consumption by optimizing the
conversion of Methanol to Formaldehyde in Reactor by reducing the concentration of feed methanol.
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Advantages…
Before After
1 Methanol Feed concentration 84% 68%
2 Reactor conversion efficiency 60% 70%
3 Unreacted Methanol fed to Distillation column
19% 13%
4 Steam to Distillation Column Re-boiler
2000 Kg/hr 1800 Kg/hr
Innovative project – 2Reducing the steam consumption by optimizing the
conversion of Methanol to Formaldehyde in Reactor by reducing the concentration of feed methanol.
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Objective:
To eliminate the fluctuations in CAC wash water fed to Crude vacuum belt filter (CBF) by automation of wash system.
System :
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 flow through Rotameter.
Innovative project – 3Reducing the water ingress into the process by
automation of Crude Belt Filter cake wash.
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ML to SF section
T-170-2
T-170-3
P 170-1 P 170-2 P 170-3
S 170
Spent wash liquor to Evaporator
Recycled wash
Feed TankT 119
PE cakeT 171
CAC Wash Header
Before :
Feed to CBF
ML
Rotameter
Innovative project – 3Reducing the water ingress into the process by automation of
Crude Belt Filter cake wash.
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Constraints 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.
Innovative project – 3Reducing the water ingress into the process by
automation of Crude Belt Filter cake wash.
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T-170-2
T-170-3
P 170-1 P 170-2 P 170-3
S 170
Recycled Wash
Feed TankT 119
PE cakeT 171
CAC Wash Header
After :
Feed to CBF
ML
MF
FIC
Innovative project – 3Reducing the water ingress into the process by automation of
Crude Belt Filter cake wash.
ML to SF section
Spent wash liquor to Evaporator
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Advantages:
Steam savings to the tune of 968 Tons/annum
Consistent cake purity leading to better process stability.
Production capability increased by 1.3%
Before After
1 Average CAC wash rate. 12 lpm 10 lpm
2 Steam consumption forRe-evaporation
720 Kg/hr 600 kg/hr
Innovative project – 3Reducing the water ingress into the process by
automation of Crude Belt Filter cake wash.
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ENVIRONMENTAL IMPROVEMENT PROJECTSInstalled Methanol and Formaldehyde storage tanks vent collection andrecycling system at a cost of 11.7 RL to eliminate VOC emissionsthrough tank breathing.
Installed a over head spray nozzles in the ash yard to ensure completesuppression of dust at a cost of 4.5 RL. This is in light of the recentCPCB’s recommendations of PM 2.5
Installation of Sophisticated Dust Collecting System to keep the Boilerstack emission SPM levels to less than 50 mg/Nm3.
Contd . . .
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ENVIRONMENTAL IMPROVEMENT PROJECTSWe have installed a RO system followed by MEE and ATFD to become aZero liquid discharge unit with respect to liquid effluent. We recyclealmost 90% of the effluent generated. Project cost: 1.3 CrWe have implemented LDAR system to track fugitive and point sourceemissions. Project cost: 4.2 RLInstallation of Rupture disc at upstream of Acetaldehyde bullet safetyvalves. Project cost: 4.3 RLWe have developed Green Belt over more than 45% of the total factoryarea.
Contd . . .
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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.
Contd . . .
Before After
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ENVIRONMENTAL IMPROVEMENT PROJECTSOnline 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.
Contd . . .
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RAIN WATER HARVESTING AT SITE
Contd . . .
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Tree plantation
By our Chairman By ISO Auditors
By DEE, TNPCB By Employees
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THERMAL ENERGY : -
Total Steam flow from the boiler to the plant is measured using“Pressure & Temperature Compensated” Vortex Steam Flow meter.
Steam flow measurement systems are available for measuringindividual 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 adequatelyreasoned out.
Yearly steam audit by external competent agency
Steam trap monitoring by external agency
ENERGY MONITORING FORMAT & METHODOLOGY
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Daily monitoring format – Thermal Energy
ENERGY MONITORING FORMAT & METHODOLOGY
April 2012 Steam Generation MT Water Consumption kL
Penta Steam MT
Water - SteamBalance
Power gen. kW-hr
EB Cons kW-hrPower / MT
SteamStock on hand MT (06:00 hrs)
Coal Receipt MT
Coal Consump. MT
Penta Prod MTDATE SH Steam MT SAT Steam MT DSH Steam MT
Vented Steam MT Hot Cond DM Water
TG DG
01-04-2012 0.00 0.00 0.00 0.00 0.00 50.00 0.00 -50.00 0 2760 0 #DIV/0! 581.67 0.00 0.00
02-04-2012 0.00 0.00 0.00 0.00 0.00 18.00 0.00 -18.00 0 3540 0 #DIV/0! 581.67 0.00 20.00
03-04-2012 227.00 24.50 15.70 2.90 131.00 181.00 251.50 -44.80 13550 1628 32 59.69 581.67 118.03 50.0 20.00
04-04-2012 277.00 38.00 19.40 0.80 248.00 54.00 315.00 32.40 19700 0 100 71.12 649.70 0.00 61.0 32.50
05-04-2012 287.00 39.90 20.00 0.10 270.00 55.00 326.90 21.90 20750 0 52 72.30 588.70 0.00 63.4 12.00
06-04-2012 289.00 42.40 20.20 0.00 271.00 53.00 331.40 27.60 21670 0 60 74.98 525.30 53.33 64.0 15.75
07-04-2012 290.00 43.00 20.20 0.20 265.00 55.00 333.00 33.20 21800 0 0 75.17 514.63 116.92 64.6 14.75
08-04-2012 290.00 44.90 20.50 0.10 265.00 43.00 334.90 47.40 21800 0 0 75.17 566.95 154.04 64.7 14.50
09-04-2012 296.00 40.80 20.60 0.80 270.00 57.00 336.80 30.40 22050 0 136 74.49 656.29 0.00 65.0 15.50
10-04-2012 300.00 37.30 20.80 1.80 253.00 60.00 337.30 45.10 22660 0 56 75.53 591.29 21.89 65.3 19.25
11-04-2012 290.00 37.20 20.20 0.20 263.00 51.00 327.20 33.40 21620 0 72 74.55 547.88 73.47 63.3 13.00
12-04-2012 294.00 39.50 20.50 0.40 104.00 53.00 333.50 197.00 21650 0 104 73.64 558.05 0.00 64.5 13.00
13-04-2012 298.00 41.90 20.50 0.60 300.00 47.00 339.90 13.40 21530 0 68 72.25 493.55 69.70 65.8 14.75
14-04-2012 297.00 42.10 20.80 1.40 300.00 47.00 339.10 12.90 22070 0 0 74.31 497.45 20.40 65.5 15.25
15-04-2012 295.00 43.50 20.60 1.50 300.00 44.00 338.50 15.10 21590 0 0 73.19 452.35 30.96 65.3 13.00
16-04-2012 300.00 44.00 20.80 1.20 300.00 56.00 344.00 8.80 22400 0 268 74.67 418.01 71.92 66.5 19.75
17-04-2012 296.00 40.00 20.60 2.90 300.00 56.00 336.00 0.60 21550 0 600 72.80 423.43 0.00 65.0 17.00
18-04-2012 304.00 41.00 21.50 2.90 323.00 58.00 345.00 -14.50 22340 0 572 73.49 358.43 55.53 66.8 17.00
19-04-2012 303.00 37.60 20.90 4.40 277.00 81.00 340.60 3.50 22010 0 648 72.64 347.16 64.70 66.0 20.25
20-04-2012 314.00 43.50 21.70 2.90 298.00 62.00 357.50 19.20 21750 0 492 69.27 345.86 0.00 69.0 18.75
21-04-2012 303.00 38.50 21.00 2.60 295.00 63.00 341.50 4.50 21850 0 0 72.11 276.86 118.84 65.8 18.75
22-04-2012 303.00 43.60 21.10 1.40 295.00 57.00 346.60 15.70 22000 0 0 72.61 329.90 58.15 66.9 15.00
23-04-2012 304.00 41.10 21.20 2.90 301.00 63.00 345.10 2.30 22210 0 316 73.06 321.15 121.03 66.9 16.75
24-04-2012 306.00 42.00 21.00 4.30 292.00 71.00 348.00 6.00 22390 0 680 73.17 375.28 75.40 67.5 13.50
25-04-2012 306.00 23.50 21.00 4.70 232.00 99.00 329.50 19.50 21470 0 856 70.16 383.18 107.85 63.8 13.00
26-04-2012 316.00 42.50 21.70 2.70 297.00 68.00 358.50 15.20 22800 0 420 72.15 427.23 52.89 69.3 11.00
27-04-2012 315.00 41.00 21.90 2.30 298.00 64.00 356.00 15.90 22400 0 668 71.11 410.82 150.34 68.9 17.25
28-04-2012 320.00 40.30 21.90 5.90 297.00 72.00 360.30 13.20 22700 0 0 70.94 492.26 0.00 69.7 9.00
29-04-2012 319.00 43.00 22.20 2.50 297.00 64.00 362.00 23.20 22550 0 0 70.69 422.56 46.88 70 1.75
30-04-2012 316.00 44.70 22.00 1.40 303.00 64.00 360.70 15.70 22170 0 396 70.16 399.44 79.11 69.8 8.00
TOTAL 8355.00 1121.30 580.50 55.80 7645.00 1866.00 9476.30 545.80 605030.00 7928.00 6596.00 72.42 1661.38 1834.30 450.00
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Monthly monitoring format – Thermal Energy
ENERGY MONITORING FORMAT & METHODOLOGY
BOILER MONTHLY REPORT April '11 May ' 11 June ' 11 July ' 11 August ' 11 September' 11 October' 11 November' 11 December' 11 January' 12 February' 12 March' 12 2011-12 AVG
STEAM SH steam generated MT 7623.00 7781.00 8563.00 7519.00 7439.00 7432.00 7962.00 8665.00 6573.00 7626.00 8248.90 8031.00 7789
Sat steam generated MT 839.61 935.40 1025.35 996.10 985.70 1018.30 1101.00 1028.76 854.38 1033.75 1210.00 1059.20 1007
LPDSH water spray MT 527.00 539.50 563.90 508.00 505.30 516.40 545.50 586.60 456.30 521.60 575.30 559.40 534
LP steam vented MT 92.60 86.73 50.40 30.70 54.30 58.90 70.90 57.30 35.30 59.40 24.70 21.80 54
Hot condensate consumption MT 7177.00 7564.00 8361.00 7539.00 7176.00 7435.00 6687.00 8460.00 6472.00 7557.00 7900.00 7175.00 7459DM water consumption MT 1803.00 1482.00 1622.00 1383.00 1351.00 1325.00 1149.00 1738.00 971.00 1622.00 1607.00 1656.00 1476
Enthalpy of SH steam kCal/kg 776.00 776.00 776.00 776.00 776.00 776.00 776.00 776.00 776.00 776.00 776.00 776.00 776
Enthalpy of sat steam kCal/kg 667.00 667.00 667.00 667.00 667.00 667.00 667.00 667.00 667.00 667.00 667.00 667.00 667Enthalpy of exhaust steam kCal/kg 707.00 707.00 707.00 707.00 707.00 707.00 707.00 707.00 707.00 707.00 707.00 707.00 707
Enthalpy of feed water kCal/kg 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110
Total water consumption MT 8980.00 9046.00 9983.00 8922.00 8527.00 8760.00 7836.00 10198.00 7443.00 9179.00 9507.00 8831.00 8934
Total steam generated from boiler MT 8462.61 8716.40 9588.35 8515.10 8424.70 8450.30 9063.00 9693.76 7427.38 8659.75 9458.90 9090.20 8796
Penta steam consumption MT 8556.41 8716.40 8776.35 8446.50 8299.30 8300.30 8766.00 8604.76 8505.00 10111.13 9458.90 9090.20 8803
FUEL
Total coal consumption MT 1441.90 1568.50 1810.40 1769.50 1533.60 1550.90 1777.80 1538.90 1600.50 1673.10 1692.20 1621.20 16326000 GCV coal consumption MT 1441.90 850.00 0.00 150.00 752.00 800.00 684.00 1455.10 960.30 501.94 846.10 500.00 745
5600 GCV coal consumption MT 0.00 718.50 1810.40 1619.50 781.60 750.90 1093.80 83.80 640.20 1171.16 846.10 1121.20 886
AFB GCV of 6000 GCV coal kCal/kg 5193.00 5193.00 5193.00 5193.00 5193.00 5193.00 5193.00 5193.00 5193.00 5193.00 5193.00 5193.00 5193
AFB GCV of 5600 GCV coal kCal/kg 4167.00 4507.32 4507.32 4507.32 4507.32 4507.32 4507.32 4370.73 4370.73 4370.73 4370.73 4370.73 4422
Avg GCV of coal kCal/kg 5193.00 4878.90 4507.32 4565.44 4843.54 4861.01 4771.13 5148.22 4864.09 4617.42 4781.87 4624.33 4805Avg coal cost per month Rs / MT 5392 4934 4381 4443 4776 4841 5190 5066 5165 5586 5397 4808 4998
CALCULATIONS
Heat input to boiler kCal 7487786700 7652557317 8160046829 8078550000 7428055024 7538944390 8482115415 7922601617 7784980339 7725400566 8091873398 7496964390 7820822999Heat output from boiler kCal 5544580770 5703163800 6274077950 5562481700 5503408900 5516905100 5915949000 6343909320 4853507660 5654714750 6167737400 5938620400 5748254729Boiler efficiency (Direct) % 74.05 74.53 76.89 68.85 74.09 73.18 69.75 80.07 62.34 73.20 76.22 79.21 73.50
Steam - Fuel ratio 5.87 5.56 5.30 4.81 5.49 5.45 5.10 6.30 4.64 5.18 5.59 5.61 5.39
TG power generated per MT steam kW/MT 72.21 71.97 71.09 72.91 72.79 74.35 75.38 73.86 73.35 73.12 75.55 74.11 73.39Specific steam cons in TG kg/kW-hr 13.85 13.89 14.07 13.72 13.74 13.45 13.27 13.54 13.63 13.68 13.24 13.49 13.63% steam vented to generated % 1.09 1.00 0.53 0.36 0.64 0.70 0.78 0.59 0.48 0.69 0.26 0.24 0.61
Fuel towards power generation MT 136.79 147.66 170.49 165.04 143.04 144.16 165.09 145.03 149.56 155.69 156.16 151.28 152
Fuel towards process applications MT 1305.11 1420.84 1639.91 1604.46 1390.56 1406.74 1612.71 1393.87 1450.94 1517.41 1536.04 1469.92 1479
Heat - Power ratio of power plant 9.09 9.09 9.09 9.09 9.09 9.09 9.09 9.09 9.09 9.09 9.09 9.09 9.09
TG Power Generation cost Rs / kW 1.34 1.30 1.23 1.34 1.26 1.26 1.43 1.15 1.60 1.56 1.35 1.22 1.33
Steam Generation cost Rs / MT 908.64 887.86 903.69 930.71 882.62 904.53 1052.56 905.99 971.91 924.35 965.58 857.49 926.41PENTA Penta production MT 450.00 450.00 450.00 450.00 450.00 450.00 450.00 450.00 450.00 450.00 450.00 450.00 450.00
Specific steam cons by plant MT / MT PE 18.81 19.37 21.31 18.92 18.72 18.78 20.14 21.54 16.51 19.24 21.02 20.20 19.55
Specific power cons by plant kW / MT PE 1347.44 1379.57 1485.94 1351.45 1310.53 1317.28 1429.18 1490.01 1153.85 1274.58 1404.50 1328.11 1356EQUIVALENT FUEL CONSUMPTION
Total coal consumed MT 1441.90 1568.50 1810.40 1769.50 1533.60 1550.90 1777.80 1538.90 1600.50 1673.10 1692.20 1621.20 1632
Avg GCV of coal kCal/kg 5193 4879 4507 4565 4844 4861 4771 5148 4864 4617 4782 4624 4805Boiler efficiency (Direct) % 1 1 1 1 1 1 1 1 1 1 1 1 1
GCV of equivalent fuel kCal/kg 3500 3500 3500 3500 3500 3500 3500 3500 3500 3500 3500 3500 3500
Boiler efficiency with equ. Coal % 1 1 1 1 1 1 1 1 1 1 1 1 1Equivalent coal consumption MT 2139.37 2207.81 2331.44 2308.16 2092.88 2146.36 2420.24 2269.65 2224.28 2207.26 2311.96 2141.99 2240
Specific equ. Coal consumption kg/MTsteam 250.03 253.29 265.65 273.27 252.18 258.59 276.09 263.77 261.53 218.30 244.42 235.64 254
Steam Cost (Coal handling charges not included)Budjeted steam cost Rs / MT 842 842 842 842 842 842 842 842 842 842 842 842 842
Actual steam cost Rs / MT 909 888 904 931 883 905 1053 906 972 924 966 857 925
% Variance wrt budget -7.91 -5.45 -7.33 -10.54 -4.82 -7.43 -25.01 -7.60 -15.43 -9.78 -14.68 -1.84 -9.82
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Efficiency is calculated on daily basis by direct method.Belt Weighment scale is fixed in the feed belt conveyor & used formeasuring fuel quantity.Boiler energy audit is carried out once in a year by expert consultants.90 to 95% of hot condensate is returned to boiler.All critical parameters of the captive plant are connected on line toManagers/Executives for effective monitoring through internet.
COGEN PLANT EFFICIENCY
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Electrical power tree is prepared to monitor fixed and variable powerconsumption.
KWhr consumption is monitored for overall plant and individualsections and the consumption is compared with production and anyvariation is reasoned out.
Equipment running hours are monitored on daily basis to identifyidle running/under loading of the machineries
Utility report is generated on daily basis which captures specificpower, steam and water consumption.
Any deviation of the specific consumption figures from the “Budget”is captured in terms of LOSS/GAIN in Rupees on daily basis.
ELECTRICAL ENERGY
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MODEL ENERGY MONITORING FORMAT
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MODEL ENERGY MONITORING FORMAT
Daily Power consumption report
Monthly Power consumption report
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Energy week is celebrated in the month of December to emphasize theimportance of energy conservation across the factory.
Energy conservation related ideas received from employees throughsuggestion scheme is evaluated, ideas worth implementing arerewarded with “Energy Efficient Gadgets”
Total no of suggestions received in 11-12 - 22
No of suggestions implemented - 17
On completion of the project, IRR projected and IRR actually realized iscompared.
To improve the awareness on Energy conservation, CFL lamps issued toall daily contact workmen during the safety week celebrationsMarch’2012.
IMPLEMENTATION OF SUGGESTIONS
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Replacement of 150W SV lamps with 45 W LED street light fittings.
IMPLEMENTATION OF SUGGESTIONS
Before After
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RENEWABLE ENERGY PROJECTS
Installed Natural draft air ventilators on top of Stores, Workshop and Boiler, investment made RL 1.55 and Savings RL 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 in the Boiler.
Contd . . .
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RENEWABLE ENERGY PROJECTS
Solar Water heating system to Industrial Dish Washing application in canteen at a cost of RL 2.2, thereby achieving saving of 1.18 RL/annum.
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Reduction of throttling losses across TG by Modification of Nozzleplates.Reducing the head pressure of Boiler De-aerator feed water pumps.Installation of VFD for Instrument Air compressor.Power conservation by effluent reduction at source.Reducing the surface moisture of coal by installing Turbo ventilatorsin Coal storage sheds.Replacement of worm gear with inline helical gear for ETP aerator.Replacement of pneumatic level instruments with Electronic type.Installation of Energy Monitoring System.Optimizing the power consumptions of Vacuum pump in Crude BeltFilter.Replacement of conventional Light fittings with LED fittings and Lightpipe.Installation of solar systems for lighting requirements.Continuing with phase wise replacement of standard motors withEFF1 motors.Encourage employees to qualify as Certified Energy Manager/Auditor.
ENCON efforts for future…
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Best practices on energy front implemented through our associates
Persuaded the coal suppliers to shift importing of coal from 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.While evaluating the quality of imported coal, special weight age is given for ash and sulphur 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.
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IMPLEMENTATION OF CORRECTIVE / PREVENTIVE ACTIONS FROM ISO 14001 / OHSAS 18001 CERTIFICATION
Sl.No Standard Description and
ConsequenceCategory of
FindingCorrective
actionsPreventive
Action1 ISO
14001:2004Requirement: 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 Room (MCR):- Noise emanating from the MCR AC Compressor is on the higher side. Noise level monitoring to be done here since this Compressor is running continuously
Observation/4.4.6
AC compressor area will be included in the Noise survey monitoring area and periodic monitoring of Noise will be done.
Effectiveness is being ensured during internal monthly EHS meeting.
Date of audit: 27.02.2012
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Awards and Recognitions….
We have won "The Environmental Best practices Award” for “Most Innovative Environmental project” by CII in Jan’2011
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Challenges faced during “THANE” cycloneOur plant got devastated during Thane cyclone on 30th Dec 2011With concentrated team efforts we overcame the challenges and restored the plant to achieve the targeted production.
Before Cyclone
After restoration
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EXISTENCE OF HUMAN RACE IS CENTERED
AROUND “ENERGY”
ENERGY IS THE “BREATH” OF INDUSTRY.
THANK YOU !!!
IT CAN NEITHER BE CREATED NOR DESTROYED. BUT CAN BE “CONSERVED”.