ENCON IN THERMAL SYSTEM

Transcription

1 ENCON IN THERMAL SYSTEM Orchid chemicals & Pharmaceuticals ltd. Bulk API Alathur facility Bulk API Aurangabad facility OHC (Formulations) Alathur facility R&D Centre Corporate Office OHC (Formulations) IKKT Facility 1

2 COMPANY PROFILE IN BRIEF Largest manufacturer of Cephalosporin products in India One among the top five in the world, holding a market share of % Alathur facility Turnover - Rs.598 Crs. Total Work force employed % EOU with ISO 9000, ISO 14000, US-FDA, TGA EDQM, MHRA certifications Awards Received in a. British safety council International Safety Award-2009 b. Greentech Safety Award c. G3 Award QA & QC building Sterile clean room Sterile block Thermal System (Steam) Generation Distribution Utilization 2

3 Condensate recovery Steam Generation in : 646 Ton / day Condensate water recovered : 574 KL / day Un recovered condensate water : 25 KL / day Condensate recovery : 93 % (as against std:90% courtesy Forbes) Planning to improve by 2% by converting existing direct purged steam heating system into indirect. Daily Monitoring and Reporting System Sl.no Monitoring & report Picture 1 Steam Index 2 Steam consumption Report 3 Steam condensate recovery 4 Water consumption report 3

4 Steam Generation System Furnace Oil Fired Boiler Coal Fired Boiler Waste Heat Recovery Boiler 4

5 Replacement of Conventional FO Fired Boiler with Energy Efficient F.O Fired Boiler FO Fired Conventional Boiler FO Fired Energy efficient Boiler FEED WATER IN 90 C 120 C FEED WATER IN TO ECONOMIZER O2 TRIM ELECTRONIC AIR FUEL RATIO CONTROLLER 230 C FLUE GAS 150 C 90 C FEED WATER IN FEED WATER IN Steam Fuel Ratio : C TO BOILER Steam Fuel Ratio : 15.5 (As against Ref.Forbes) FO Fired Energy efficient Boiler 5

6 Furnace Oil Fired Energy Efficient Boiler Feature Flue gas temperature reduced from 230 C to 150 C by providing economizer and feed water pre heater Electronic operated Ratiotronic System for Atomization (O 2 level < 4.0 %) Online soot blockers to remove carbon deposited on the boiler Water Pre-heater to avoid corrosion in Economizer Adequate Heat transfer area in Economizer Monitoring methodology a) Mass flow meter for Furnace oil b) Vortex flow meter for Steam c) Online trends to monitor Steam, F.O consumption, O2, CO2 percentage in flue gas Adequate Heat transfer area in Economizer Savings Lacs/ annum. Coal Fired Energy Efficient Boiler Feature Adequate heat transfer area provided in air pre heater and economiser to recover maximum heat from Flue gas Flue gas temperature reduced to 125 C against conventional system temp.of 140 C. Auto combustion system and three element controller provided to improve the combustion efficiency Blowdown water reused for ash Quenching Ash recirculation system provided to reduce the Unburnt carbon loss All ID,FD,PA Fans,Pocket feeders,feed water Pumps are installed with Variable Frequency Drive Motors 6

7 Coal Fired Energy Efficient Boiler Feature Monitoring methodology Mass flow meter for Steam Coal consumption based on Pocket feeder speed Online trends to monitor All compartments temperature and Pressure at difference zones On line analyzer to monitoro2, CO,SPM,SOX, NOX percentage in flue gas On line conductivity meter to ensure water quality Steam fuel Ratio is maintaining around 7.25 for a coal of CV of 5500 Kcal/Kg Coal Fired Energy Efficient Boiler 7

8 Waste Heat Recovery Boiler Increasing Tonnage Existing system : Modified system : STEAM OUTLET 1.8 T/Hr STEAM PRESSURE 10 Bar STEAM OUTLET 2.5 T/Hr STEAM PRESSURE 10 Bar ECONOMIZER m3/hr 230 C m3/hr 170 C 400 C 400 C CPP 3.8 MW CPP 3.8 MW Steam Generation : Bar Steam Generation : Bar Features: Boiler Heat transfer area increased to 30% Economiser provided to preheat feed water On line soot blower provided to remove carbon deposit Savings : hrs Operation Savings : hrs Operation Distribution Steam trap condition monitoring Every 15 days once Forbes marshall study reveal that steam loss through traps< 1% (4% for other Pharma plants) Insulation study being carried out every year. Flow meters are provided for major steam consumers and the online monitoring system provided. 8

9 HP GENERATION :506 TPD EVAPORATOR PEE CONCENTRATOR CRYSTALIZER RECOV ERY PRODUCTION LPGENERATION :225 TPD RECOVERY PRODUCTION AHUS Monitoring & Improvement 9

10 Utilization Specific steam consumption reduction in effluent evaporation system Optimization of distillation column operation using Aspen Software (Simulation Technology) Optimum utilization of Energy in Water for injection system (WFI) and Air Handling Units (AHU) Reduction of Specific Steam Consumption in Effluent Evaporation System Result: Tons/KL reduction in Specific steam consumption & Annualised savings ` Lacs / annum Earlier Process: Steam Bar Feed 2% salt Pure steam to Production & recoveries 2.5 Bar Secondary boiler E-101 Impure cond. to CT /ETP DM water 35 10% salt Feed 35 Tons/ day Modified Process: Steam Bar Feed 2% salt E-101 Feed % salt Pure steam to Production & recoveries Impure cond. to CT /ETP Secondary boiler Bar 6.4 Tons/ day DM water HE-101 CT water Out HE-101 CT water Out Steam cond. to Boiler Steam Ton / day 80% salt Salt separator Reactor Steam condensate to Boiler CT water In Impure condensate to ETP Steam cond. to Boiler Steam Fast Loop Pump Ton / day 80% salt Salt separator Reactor Steam condensate to Boiler CT water In Impure condensate to ETP Specific Steam consumption : Tons/KL of feed Problems Faced :- Frequent chocking of tubes in HE-101 Dish end Long period for cleaning 6 Days Specific Steam consumption : Tons/KL of feed Action taken :- Fast loop pump introduced to reduce the tubes chocking High pressure hydro jet introduced for cleaning 01 day for cleaning Specific steam consumption saving : Tons / KL ; Net Saving achieved : ` Lacs / annum 10

11 Optimization of distillation column operation using Aspen Software (Simulation Technology) Features of Aspen Software : The column operations can be optimized based on energy, impurities, etc. and various constraints like condenser & reboiler duty. Detailed heat and mass balance Can be calculated for all the unit operations like heater, cooler, condenser and reboiler load for distillation column. For reducing energy various scenarios can be simulated using sensitivity analysis e.g. change of column pressure, reflux ratio, feed tray location, etc. Using batch reactor model, we can calculate the optimum reaction time & temperature in a batch reactor Optimization of distillation column operation using Aspen Software (Simulation Technology) Existing Practice :Reflux ratio was maintained 8 to separate Ethyl Acetate (EA) & Tetra Hydro Furan(THF) from EA+THF mixture Modified Practice :Reflux ratio was reduced to 5 from 8 to separate EA & THF from EA+THF mixture without affecting the quality Investment : ` 2 Lacs Savings : ` 17 Lacs/Annum (In terms of steam reduction) 11

12 Optimization of distillation column operation using Aspen Software (Simulation Technology) Earlier Process: FLAME ARRESTOR Modified Process: FLAME ARRESTOR CT Water Outlet CT Water Inlet Primary Condenser (81 m2) -10 C Secondary Condenser (10 m2) CT Water Outlet CT Water Inlet Primary Condenser (81m2) -10 C Secondary Condenser (10 m2) 5400 Kg 4500 Kg Solvent feed 1000 Kg C 1104 Reflux FT 4800 Kg FT collection 600 Kg LS RD Solvent feed 1000 Kg C 1104 FT Reflux 3625 Kg LS RD Kg FT collection Re-boiler Re-boiler Reflux ratio : 8.0 Reflux ratio : 4.14 Net Steam reduction 2.5 Tons/Batch & 1700 Tons/ annum Investment : ` 2 Lacs & Savings : ` 17 Lacs/Annum (In terms of steam reduction) Optimum utilization of Energy in Water for injection system (WFI) and Air Handling Units (AHU) Existing system : Modified system : 0 c Out AHU SYSTEM +60 c In 10 µ WATER FOR INJECTION SYSTEM +80 C IN +60 C OUT 0 c Out AHU SYSTEM +60 c In WATER FOR INJECTION SYSTEM +80 C IN 10 µ +60 C OUT +10 C OUT +10 C +5 c Out +10 c Out +35 C IN RECEIVER +5 c Out +10 c Out +35 C IN RECEIVER OUT CONDITIONED AREA PURIFIED WATER CONDITIONED AREA PURIFIED WATER Steam was used to heat the dehumidified air in AHU and 0 C brine is used to cool the pure steam generated in WFI system Water is being used to cool the pure steam generator and hot water which is coming out from the WFI is circulated to AHU heating coil Investment Savings Achieved : ` 1 Lacs : ` 44.7 Lacs/Annum 12

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