ENERGY CONSERVATION IN CHEMICAL INDUSTRIES

CASE STUDIES

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By

ENERGY CONSERVATION

• The quickest, cheapest and the most practical

method of energy savings.• Energy is a manageable expense, and it can be

easily controlled through dedicated efforts.• “communication, culture and commitment are

the key driving forces for us in making ‘conservation of energy a way of life’ at our works.

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• The latest is LED lighting . A 15 watt CFL can be replaced by 7 watt LED . And the carbon emission level is 8 gm /hr.

Ref- BEE EA text book

ENERGY MANAGEMENT STRATEGIES

1. Energy Conservation If you don’t need it turn it off.

2. Energy Efficiency If you need it do it more efficiently

ENERGY TRANSFORMATION

About GSFC…...• GSFC is an integrated complex for

manufacturing of Fertilizers, Petrochemicals, Polymers, Fibers etc.

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• GSFC also have in built Co-Generation system to make complex, self sufficient for the need of power and steam.

• GSFC has installed capacity of 124 MW of wind mill.

THE MAIN REASONS FOR HIGHER SPECIFIC CONSUMPTIONS IN INDIAN INDUSTRIES

Obsolete technology.Lower capacity utilization.Casual metering and monitoring of energy

consumption.Lower automation.Poor raw material quality.Poor handling, operating and maintenance

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AREAS IN WHICH ENERGY CONSERVATION IS POSSIBLE

• Power Pumps, compressors, fans, blowers

• Steam Steam production & distribution network

• Natural gas Furnaces

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COST OF ENERGY

• Power =Rs. 7.5 / kWh =• Steam =Rs. 2720 / MT=• Natural =Rs. 34 / SM3 = Gas

NCV of Natural gas = 8400- 8700 Kcal/sm3

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8.7 Rs/1000Kcal 4.18 Rs/1000Kcal 4 Rs/1000Kcal

Enthalpy of steam = 650 Kcal/kg

Energy Management Cell, WBSEB

SECTOR WISE ENERGY CONSUMPTION

Type of Consumer Percentage of Consumption

Agricultural 5

Industry 49

Transport 22

Residential 10

Others 14

Agricultural

Industry

Transport

Residential

Others

ENERGY SAVING OPPORTUNITIES IN STEAMDesuperheating of steam

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P = 37 Kg/cm2.gT = 350 0CM = 40 MT/Hr

PCV

P = 20 KT = 320 0C

Desuperheater

BFW

P = 20 Kg/cm2.gT = 250 0CM= 43.4 MT/Hr

Super heated steam acts as an inert gas and hence reduces heat transfer coefficient.

Desuperheating resulted into more steam generation by ~3.5 MT/Hr.

It can result into capacity limitation at higher load.

STH

THERMO-COMPRESSOR SYSTEM

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LPS

HPS

THERMO COMPRESSOR TECHNOLOGY

• Useful when low pressure steam is being vented / condensed.

• Requirement of medium pressure steam is met by throttling high pressure steam.

• Higher pressure of MPS requires high amount of HPS.

• Quantity of MPS determines recovery rate of LPS.• Very attractive pay back period.• Becoming popular.

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POWER SAVING IN COMPRESSORS• Provision of Inter stage coolers.• Adequate CW supply to inter stage coolers.• Clean heat transfer surface of Inter stage

coolers.• Low inlet temperature of feed gas.• Low temperature of cooling water.• Less handling of inlet mass.• Reduce the discharge pressure of

compressor if process permits

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power saving done in centrifugal compressor by reducing discharge pressure from 11.5 kg.cm2 to 11 kg.cm2 .g

Power saving=1.73*11*4*0.9=68.5 kw68kwh*7.5 Rs/unit= Rs 513 per hr

• BEFOREAMP Drawn=54

• AFTERAMP Drawn=50

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CASE STUDY- 1POWER SAVING IN COMPRESSORS

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CASE STUDY-2POWER SAVING IN COMPRESSORS

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CASE STUDY-2POWER SAVING IN NH3 COMPRESSORS

• LESS HANDLING OF INLET MASS• 24% NH3 solution preparation scheme:• Liquid ammonia is supplied as refrigerant. Vapour

ammonia generated due to absorption of process heat was supplied to Reciprocating vapour ammonia compressors.

• Part of vapour ammonia absorbed in DMW to prepare 24% NH3 solution, which is required raw material in Capro-Lactam plant.

• Resulted into less power consumption by compressors due to reduction in loading step for Reciprocating vapour ammonia compressors.

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CASE STUDY-3 : WASTE HEAT UTILIZATION

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E-405-5

CW

D-405-3

LBP column-II T-406-2

HE

T=135 0C

T=95 0C

T=50 0C

T=50 0C

T=85 0C

H2

Dehydrogenation product

Steam saving = 140 Kg/Hr (1120 MTPY)(Rs. 16.8 lacs/Yr), Cost of modification = ~Rs. 5 lacs Payback period = 0.3 years

ENERGY EFFICIENCY IN PUMPS

4. Trimming of impeller.

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1. Optimization of pumping system.

Following are the ways to improve performance and there by to reduce power consumption.

3. Improving network system to reduce pumping requirement.

5. Replacement of old and inefficient pump with new and higher efficiency pump.

2. Installation of optimum size pump/motor

CASE STUDY-1-Trimming of impeller

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Liq NH3 to consumers P=~17 barg

P-601-A

Vap NH3 to Ref. comp.

MP Flash drum

LP Flash drum

NH3 storage tank

L= ~2 Kms

VO = 5 %

Flow m3/Hr Pressure bargPower kWhImp.dia. mm

Design820735325

Before1810.327325

Recent186.720264

56 m3/Hr

P= 0.5 barg

Power saving = 0.56 lacs units /yr (Rs. 4.2 lacs /yr

VO = 10 %

Liq. NH3

LCV

CASE STUDY-2- Trimming of impellerCase of proper capacity utilization

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FV-402-01

E-402-1 E-402-2 E-402-4To T-402-1 (8.80

kg/cm2)

press= kg/cm2

P-404-1A/1B

FT-402-01

SKETCH FOR SUGGETION OF P-404-1A/1B

17.5

17 10

D-404-1

3.8

CASE STUDY-2-Trimming of impeller

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Impeller of the above pump trimmed & motor of the pump replaced by 75 kw, earlier it was of 90 kw

Before AfterMotor, kw 90 75

Impeller diameter,mm 355 340

AMP 100 90power drawn(kwh) 64.6 58.2

Rs/kwh 7.5 7.5

RS 484.6 436.2

SAVING RS/Hr 48.5

SAVING RS/Yr 387693

Pump follows following equations after Trimming of impeller(Affinity laws)

• Q2/Q1 = D2/D1

• H2/H1 = (D2/D1)^2

• P2/P1 = (D2/D1)^3

Where, Q = Flow in m3/Hr, H = Head in meters and HP = power in kWh, D= impeller diameter

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CASE STUDY-3 Installation of higher efficiency pump

/ Improvement in efficiency

CW circulation pump (P-012-1A/B/C), Caprolactam-I Plant:

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• CW pumps were running since commissioning of plant in 1974. Based on survey carried out, pumps were found running at very low efficiency -55 %

• New set of pumps installed having higher head, capacity and better efficiency.

INSTALLATION OF HIGHER EFFICIENCY PUMPS..(CONT)

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6 meter elevation

12 meter elevation

18 meter elevation

24 meter elevation

From CT basin

It is possible to meet plant requirement at 110 % load.

Pump ή = 55%Pump ή = 80%

BEFOREM= 5800 m3/HrH = 35 meterP = 980 kWhή = 55 %AFTERM= 6800 m3/HrH = 40 meterP = 990 kWhή = 80 %

Power cons/m3 circulation Before = 0.169 After = 0.146

Booster pumps

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WHAT IS OUR ROLE?

Energy conservation becomes our joint responsibility, be it the industries, individual citizens, organizations, oil companies, or the government.

Each one of us has a specific and significant role to play.

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CONCLUSION

∑(Little Ideas)= Big Result

∑(Wisdom + Effort) = Reduction of Energy

Cost Without Investment

Many Drops Make a SHOWER

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