RELIANCE INDUSTRIES LIMITED NAGOTHANE MANUFACTURING DIVISION

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Emmeline Pitts
6 years ago
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1 First Prize Petrochemicals RELIANCE INDUSTRIES LIMITED NAGOTHANE MANUFACTURING DIVISION Raigad (Maharashtra) Unit Profile Nagothane Manufacturing Division (NMD) is one of the six major manufacturing sites of RIL, located in Raigad district of Maharashtra. NMD is a petrochemical complex commissioned in the year Various production units in the complex are producing Polyethylene, Polypropylene, EO and MEG totaling 600 KTA per year. Production Capacity of the plant Product Capacity Capacity Utilization in % KTA Ethylene + Propylene EO+MEG LDPE LLDPE/HDPE PP BUTENE Energy Consumption Energy requirement of the complex is met by captive generation of steam & power in Captive Power Plant (CPP) with the help of Gas Turbine Generators, Steam Generators and Steam Turbine Generators. CPP imports power from MSEDCL (Maharashtra State Electricity Distribution Company Limited) distribution grid as per operation philosophy. Energy Index for last four years 190

2 Energy Conservation Measures Taken 1. Up-rate of GTG- 50: Saving in fuel & Power cost by: Improved heat rate, higher efficiency (by load transfer from ST to GT) & avoiding power 2. Small air compressor installed 3. CCC implementation in CG and C3R compressors 4. Lighting modification in all plants 5. ONE SEAL oil pump stoppage in LLDPE tr1 6. STG overhaul and performance restoration 7. Replacement of 2 SL steam float traps and 15 passing by pass valve replacement 8. Instrument air leak rectification during April'13 turn around Other Initiatives taken for achieving Energy Excellence 1. ISO certification received in the year Group of engineers have been trained and certified as ISO auditors. 2. Fuel hierarchy published monthly for optimization of CPP operation. 3. Maximum utilization of the cracker generated waste fuel gas in CPP. 4. Optimization of power import w.r.t site demand and fuel scenario. 5. Efficient operation of furnaces 6. Better Steam trap management. Periodic surveys conducted and attending losses. 7. Identification, accounting and reduction of complex hydrocarbon loss. 8. Energy efficiency as a criterion during procurement of equipment or service. 9. Minimum power generation from condensing steam turbine. 10. Periodical audits of highly Energy intensive equipments are done and taking action on the gaps. 11. Site Energy Cell Engineers have been trained for Prosteam software which is helpful for utility balance and Super-target software which is helpful for heat exchanger network and heat integration study based on Pinch concept. 12. Participation in Global benchmarking activities and taking actions to minimize the gaps with respect to global/national level. 13. Prosteam optimizer has been developed. By taking real time data, the optimizer gives recommendations to minimize total operating cost of the site by reducing letdowns and vents, and loading more efficient equipments within the given constraints. It also optimizes between purchased power and the power generated captively. The optimizer runs every hour in auto mode. It fetches data from IP21 for 15 mins. average time span and gives recommendations. 14. Energy Consultant has been engaged for revolutionizing the Energy Management System in Reliance. Engaged with SME experts for energy areas like Process, Power, and HVAC. 15. Energy management consultant for studying opportunities in heat integration. 191

3 Energy Policy 192

4 Certificate of Merit Petrochemicals PANIPAT NAPHTHA CRACKER Panipat (Haryana) Unit Profile Panipat Naphtha Cracker, the largest Naphtha Cracker in India, was commissioned in March There are five main Process units in the Naphtha Cracker Complex: Naphtha Cracker & Associated units, Polypropylene Unit, LLDPE/HDPE Swing Unit, HDPE Unit and MEG Unit. NCU produce mainly Polymer Grade Ethylene and Polymer Grade Propylene. It also produces Hydrogen, Methane off gas, Pyrolysis Fuel Oil (PFO) and other products like raw C4 mix, raw Pyrolysis Gasoline that are further processed in Associated Units. Energy Consumption Specific Electricity Consumption in kwh/ton of Product Units Naphtha Cracker Unit Poly Propylene SWING High Density Polyethylene Mono Ethylene Glycol

5 Naphtha Cracker Unit Poly Propylene SWING High Density PolyEthylene Specific Electrical Energy Consumption in KWHr/Ton of Product Mono Ethylene Glycol Specific Electrical Energy Consumption in KWHr/Ton of Product Specific Thermal Energy Consumption in M kcal/ton of Product Units Naphtha Cracker Unit Poly Propylene SWING High Density Polyethylene Mono Ethylene Glycol Naphtha Poly Propylene SWING High Density Mono Ethylene Cracker Unit PolyEthylene Glycol Specific Thermal Energy Consumption Million kcal/ tonne Specific Thermal Energy Consumption Million kcal/ tonne Energy Conservation Measures Taken 1. Interconnection between HSD pump discharge headers of individual Gas Turbines (GTs) An interconnection has been provided between HSD pump discharge headers of individual GTs resulting in stoppage of 2 nos. of HSD pumps of power rating 9.33 kwh each. Investment : Rs Lakh. Electricity saving : 0.41 Lakh kwh. 194

6 2. Routing of NCU s FCC C3 dryer Bed changeover s Residual Propylene to Fuel Gas header In NCU FCC C3 dryer, during bed changeover residual Propylene was earlier flared, which has been routed now to Fuel Gas header in controlled manner avoiding low-temperature in downstream piping thereby leading to savings of 300 MT/month of Hydrocarbon using existing dryer depressurizing line to Fuel gas. Investment : Nil Fuel saving : 3795 MTOE 3. Steam trap survey for CPP and NCU Steam trap survey for CPP and NCU was conducted in June 13 & identified traps were replaced in Sept 13 resulting in saving of 2 TPH steam loss. Investment : Rs Lakh Fuel saving : 1125 MTOE. 4. Utilizing ETP slop oil as a PFO blending component. At PNC ETP, slop oil is being recovered as a side stream from waste water through OWS and CRWS treatment process and based on the experimental results at lab, it was proposed to mix the slop oil maximum up to 5% with PFO (Flash Pt. of blend 56 C). Hence, 418 Tonnes of Slop Oil has been blended with PFO from Jan'14 till March'14 resulting into saving of Rs Cr./year. The issue of Slop Oil disposal has also been resolved effectively. Investment : Rs Lakh Fuel saving : 395 MTOE. 5. Change of Operation philosophy of Poly Propylene extruders PP unit has two extruders, each one operated by 12.5 MW Motor. Extruder can be operated in two speeds (190/243 rpm) by means of lever arrangement. Since commissioning it was being operated at high speed. As a pellet cutting improvement measure, the operation philosophy was changed to low speed from high speed operation. It yielded energy saving to the tune of kwh (Both lines total). Investment : Nil Electricity saving : Lakh KWh. 195

7 Energy Policy 196

8 Certificate of Merit Petrochemicals Unit Profile ASIAN PAINTS PHTHALIC DIVISION Ankleshwar (Gujarat) Asian Paints is India's largest paint company and ranked among the top ten Decorative coatings companies in the world. Asian Paints along with its subsidiaries have operations in 17 countries across the world with 23 paint manufacturing facilities, servicing consumers in over 65 countries. Vertical integration has seen Asian Paints diversity into products such as Pentaeryttritol (Penta) manufactured at Cuddalore in Tamil Nadu (India) in 1987 and Phthalic Anhydride 'PAN' at Ankleshwar in Gujarat in Both these chemicals are key raw materials for paint production. Manufacturing of Phthalic Anhydride involves high temperature oxidation of Ortho Xylene generating large amounts of heat recovered in the form of 22 bar steam. This is in turn used for generating power making the plant self-sustained on power front. 197

During full capacity plant operation, power consumption from external source i.e grid or DG sets is zero units now and the natural gas consumption is 2000 m 3 /day.

9 During full capacity plant operation, power consumption from external source i.e grid or DG sets is zero units now and the natural gas consumption is 2000 m 3 /day. This was mainly achieved through innovative and one of its kind energy conservation schemes. The initial steam turbine of KKK, Germany make, designed for 1190 kw, 20 bar, 340 C superheated steam with specific steam consumption 8.5 kg/kw, was replaced by Triveni make steam turbine in December, 2000 for a specific steam consumption of 7.1 kg/kw for same steam conditions. Description KKK Turbine Triveni Turbine Duration till date Steam consumption, kg/hr Specific consumption, kg/kw Power generated, kw This energy efficiency scheme along with various energy saving schemes like AC drives in centrifugal pumps, FRP blades in cooling towers, etc. has saved steam of 1000 kg/hr at 22 bar pressure. An innovative idea for converting the energy from this excess steam was developed for heating thermic fluid oil (Ilexan) used in the oxidation section up to 200 C and reduced natural gas consumption by 2000 m 3 /day. The Triveni make turbine was further upgraded in the year 2012 by increasing the number of steam stages and increased the efficiency from 7.1 kg/kw to 6.3 kg/kw resulting into reduction of steam consumption by 1000 kg/hr. Again this excess steam was used for pre heating Therminol -66 oil used in the distillation up to 198

10 270 C. This scheme has reduced the natural gas consumption from 3500 m 3 /day to 2000 m 3 /day as on today. The compressed air system for instrument air, nitrogen and plant air for ejectors were being met by operating two compressors at 7 bar discharge pressure. By segregating the different users at different pressure level and by replacing the air compressors, 20% reduction in power (30 kw) is achieved. In addition higher air discharge temperature (150 C) is now used directly in ejectors and reduced steam consumption 100 kg/hr at 6 bar pressure. Energy indices e.g. Specific Energy Consumption, MTOE (Million Tonnes of Oil Equivalent) and company s efforts to improve energy conservation. Plant operation is greatly affected in terms of energy during catalyst replacement year due to plant operation on lower capacity due to process of catalyst activation. Year & were catalyst replacement year. Normal capacity operation years are non-catalyst replacement years i.e , & Specific Energy Consumption TOE / MT Reduction by 30% wrt year Plant load (KW) New AIS Blower with VFD, Saving- 5.5 KW Plant air compressor replaced with screw -comp KW Modification in Ilexan system - 10 APR MAY JUNE JUL AUG SEP OCT NOV DEC JAN FEB MAR 199

120000 110000 100000 90000 80000 70000 60000 50000 114199 105732 93165 82032 N. Gas Consumption 106334 91745 88810 77515 62289 57242 62050 51711 I.

11 N. Gas Consumption I. Basic concept on the modified energy plant related to specific measures Natural gas prices have been increased by 184% in last 3 years. So, since last three years, unit endeavour was to reduce the natural gas consumption by efficiency enhancement in plant and machineries & by effective utilization of steam energy. Unit adopted total energy integration strategy approach (point c.) and could reduce natural gas consumption significantly. Unit could reduce the specific natural gas consumption by 28% on annual average basis wrt year Current level of specific natural gas consumption is 46% lower than year II. Effective reduction in energy consumption, both, in absolute terms of inputs for given unit of output & overall saving realized qualitatively and quantitatively. 200 Year Specific consumption Sp. Natural gas consumption TOE / MT SM 3 /MT Major Energy conservation projects Year Actions Effect Replacement of plant air compressor 34 kw power saving Modification of Ilexan hot oil circulation 10 kw power saving system Replacement of pumps and motor with 12 kw power saving energy efficient equipment (Turbine cw pump, cold oil pump-2) Process flow control through VFD 11 kw power saving (Therminol circulation pump, HP BFW

12 Year Actions Effect pump, Hot oil pump), AIS blower flow control through VFD Replacement of light fittings with LED 9 kw power saving Process optimization of thermic fluid heat duty in distillation 1500 sm 3 /day natural gas III. Greenhouse Gas inventorization and changes in last 2/3 years Total Equiavalent CO 2 Emmision (in MT / annum) As per US EPA calculation Reduction by 923 MT wrt IV. Specific power and fuel consumption At normal capacity of plant operation, our plant is power free from external sources also and further we have reduced our fuel consumption also significantly: Sr. No Parameters Specific power consumption from external sources Specific fuel consumption for thermic fluid heaters Unit of measure Design Parameters Current Parameters Units / MT Kg / MT

RELIANCE INDUSTRIES LIMITED Vadodara Manufacturing Division Vadodara (Gujarat)

First Prize Petrochemicals RELIANCE INDUSTRIES LIMITED Vadodara Manufacturing Division Vadodara (Gujarat) Unit Profile The Reliance Group, founded by Dhirubhai H. Ambani (1932-2002), is Indias largest