ROHM AND HAAS (INDIA) PRIVATE LIMITED TALOJA UNIT

Transcription

1 First Prize Chemicals ROHM AND HAAS (INDIA) PRIVATE LIMITED TALOJA UNIT Raigad, Taloja (Maharashtra) Unit Profile Rohm And Haas Company was established in 1907 in Esslingen to manufacture & sell technologically superior and unique chemical product for leather industries. Rohm And Haas Company develops specialty & performance materials for customers; products are sold around the world & used in many industrial and consumer product applications worldwide including Building & Construction, Electronics, Food & Retails, Household & Personal care, Industrial Process, Packaging and Transportation & Water. Rohm And Haas Company started operations in India in 1995 through its subsidiary Rohm And Haas (India) Private Limited and thereafter established its manufacturing unit at Taloja, India in August 2003 to manufacture Water Based Latex Polymer - (DCM- Dow Coating Material) and Polyester & Polyurethane - (Advance Functional Material). This plant is on 70,000 m 2 plot having most advanced automation & process control design. The Taloja Plant is IMS certified company for ISO-9001:2008, ISO-14001:2004, ISO-18001:2007 & Responsible Care. Energy Consumption Taloja Plant considers energy saving as a multi disciplinary approach. The energy conservation projects have resulted in both tangible and intangible savings Energy Conservation Program Savings EC Projects Lakh Lakh 12 Nos. Specific Energy Consumption Reduction Achievements With implementation of all energy conservation measures in 2013 both Electrical & Thermal energy consumption reduced in 2013 compared to 2012 as evident in below matrix & graphs. 59

2 Description Unit Total Electrical Energy Consumption Lakh kwh Total Thermal (F. Oil) Energy Consumption Total Thermal (LPG) Energy Consumption KL Lakh m Total Electrical Energy Consumption MTOE Total Thermal energy consumption in MTOE (FO+LPG) Total Production (Water Based Latex Polymer + Polyester & Polyurethane) MTOE MT Specific Electrical Energy Consumption kwh/tonne Specific Electrical Energy Consumption % Reduction in SEC Electrical over 2012 % Reduction in SEC Thermal over 2012 million kcal/ tonne % % % % 60

3 Energy Conservation Measures Taken Hot DI Water Heating System Optimization Installed VPRV, dip pipe to water circulation line & U- loop to hot water tank overflow line to eliminate vapor losses. With this change and small automation for Hot DI water heating configuration in DCS eliminated energy losses, which resulted in huge Furnace oil savings. HOT DI Tank With VPRV & First Year saving : Rs Lakh U-Loop Thermal Energy Savings : KL/Annum : Rs Lakh Hot oil Heater System Optimization Optimizing hot oil system operating parameters for loading/unloading of hot oil unit, circulation line/vessels insulation change and lean productivity approach with better production planning & co-ordination helped reduce idle losses & consistent supply of > 265 C to process resulting in batch time cycle gain and huge saving of Furnace oil. First Year saving : Rs Lakh Thermal Energy Savings : KL/Annum Hot Oil Heaters : Rs Lakh Cold DI Circulation Pump Automation Installed additional 5.5KW rated cold DI water circulation pumps apart from 22KW existing pumps and configured in DCS with operator interface enabling them to operate bigger pumps during batch process that are required for 3-4 hrs/day and smaller pumps rest of the time thus reducing idle energy losses. First Year saving : Rs 7.51 Lakh Electrical Energy Savings : kwh/annum New HE CDI Pump with 5.5 kw Motor : Rs Lakh Hot DI Circulation Pump Automation Installed additional 5.5KW rated hot DI water circulation pumps apart from 22KW existing pumps and configured in DCS with operator interface enabling them to operate bigger pumps during batch process that are required for 2-3 hrs/day and smaller pumps rest of the time thus reducing idle energy losses First Year saving : Rs Lakh New HE HDI Pump with Electrical Energy Savings : kwh/annum 5.5 kw Motor : Rs Lakh 61

4 MDI Oven Drum Toughing Time Cycle Reduction Modified the MDI oven hot air circulation ducts and lower fills, reduced the drum roller conveyor speed by installing the VFD, re distributed/ layout of the electrical heater system coils including more energy & efficient copper electrical heater coils reduced MDI drum toughing time cycle from 14 hrs to 4-5 Hrs. First Year saving : Rs Lakh MDI Drum Oven With VFD Electrical Energy Savings : kwh/annum : Rs Lakh Bester Oven Drum Toughing Time Cycle Reduction Modified the bester oven hot air circulation ducts and lower fills, modified the steam supply and its steam condensate return lines, replaced TD type steam traps with efficient TD Float type steam traps, replaced & fine tuned the TIC & Steam supply set point/logic etc reduced drum toughing time cycle from 16 to 6-7 Hrs. First Year saving : Rs 4.52 Lakh Bester Oven With TIC Electrical Energy Savings : kwh/annum Controller Thermal Energy Saving : 21.0 KL/Annum : Rs Lakh Decanter Oven Drum Toughing Time Cycle Reduction Modified the Decanter oven hot air circulation ducts and lower fills, modified the steam supply and its steam condensate return lines, replaced TD type steam traps with efficient TD Float type steam traps, replaced & fine tuned the TIC & Steam supply set point/logic etc reduced drum toughing time cycle from 16 to 6-7 Hrs First Year saving : Rs 2.96 Lakh Decanter Oven With TIC Electrical Energy Savings : kwh/annum Controller Thermal Energy Saving : 21.0 KL/Annum : Rs Lakh T1 Cooling Water Circulation pump Replacement with HE Pump Installation & Operation of single 300M 3 /hrs, 45M head, 75KW cooling water pump instead of operating 2 nos, 250M 3 /Hrs pumps to meet production plant & utilities cooling water requirement resulted in energy savings of kwh/month First Year saving : Rs 6.94 Lakh New 300M 3 /Hrs, 75KW CT Electrical Energy Savings : kwh/annum Pump : Rs Lakh 62

5 Plant HVAC optimization New 1.0 TR 5-Star Split AC Replaced Administration & laboratory buildings old 7.5 to 15TR Central A/C system with 1.0 TR 5-Star rated energy efficient split A/C for individual cabins. First Year saving : Rs 5.75 Lakh Electrical Energy Savings : kwh/annum : Rs Lakh Air Compressor loading/unloading Optimization Air compressors loading/unloading set points have been optimized to enable air compressor with VFD operate maximum time and second compressor comes online only in case the air pressure drops below 5.5 bar. First Year saving : Rs 1.50 Lakh Electrical Energy Savings : kwh/annum Air Compressor With VFD : Rs Lakh Reduction in RTO Offline energy losses Reduced Re-Therm Thermal Oxidizers offline energy losses due to trips caused by power fluctuation & high LEL in VOC by installing UPS to back its control panel & modified LEL sensor installation and air dilution after discussion with OEM. First Year saving : Rs Lakh Electrical Energy Savings : 3162 kwh/annum Thermal Energy Saving : m 3 LPG/Annum RTO Unit : Rs Lakh HOU pump replacement with HE pumps Replaced all 4 nos. 15 kw rated centrifugal pumps with 7.5 kw rated Nikkiso Make canned Motor pump having EFF1 rated motors used for circulation of thermic fluid for process heating. First Year saving : Rs Lakh Electrical Energy Savings : kwh/annum New HE HOU Mag. Drive Pump : Rs Lakh 63

6 Second Prize Chemicals IOL CHEMICALS AND PHARMACEUTICALS LIMITED Barnala (Punjab) Unit Profile IOL Chemicals and Pharmaceuticals Limited (IOLCP) is a chemicals and API s manufacturing industry, located in Barnala (Punjab). The company was started with a small project of Rs. 65 million to manufacture 4500 TPA of Acetic Acid and has now diversified into a multi product company to manufacture the Chemicals and API s Like TPA Ethyl Acetate, TPA Acetic Anhydride, 5200 TPA Acetyl Chloride, 7200 TPA Mono Chloro Acetic Acid, 9000 TPA Iso Butyl Benzene and 6000 TPA Ibuprofen. At present company s annual sales is more than USD 100 million with export to more than 50 countries Energy Consumption (Chemical Division) IOLCP has identified various Energy conservation projects, which has resulted in Energy saving and contribution to the nation in preservation of precious resources of Energy. Last two years energy consumption figures are shown below. Description Unit Electrical energy consumption million kwh Thermal energy consumption million kcal

7 Specific Energy Consumption for Chemical Plants (Chemical Division) Specific Electrical Energy Consumption Description Unit Acetyl Chloride kwh/mt Mono Chloro Acetic Acid kwh/mt Iso Butyl Benzene kwh/mt Specific Thermal Energy Consumption Description Unit Acetyl Chloride M kcal/mt Mono Chloro Acetic Acid M kcal/mt Iso Butyl Benzene M kcal/mt Energy Conservation Projects Implemented During Installation of the dopp kettle to recover solvent in Iso propyl chloro acetate plant(ipca) Spent acid, which is discharged from IPCA plant to Effluent treatment plant(etp), contains traces of solvents i.e. Isopropanol and Isopropyl chloro acetate. In order to recover these solvents, dopp kettle is installed in the process, in which under vacuum distillation of spent acid is done before the discharge of spent acid to the ETP. The unit is, now, recovering the traces of solventalong with less power consumption in the ETP. Electrical Energy saving : 0.2 million kwh/annum Total in saving : Rs. 1.4 millions Payback period : 0.5 year 2. Optimization of consumption and ratio of Potassium carbonate and Sodium metal catalyst in Iso butyl benzene (IBB) plant. In old system, Potassium carbonate and Sodium metal consumption in Iso butyl benzene (IBB) plant is at a ratio of 10:1 and consumption was 500 kg per batch. At this condition rotary vacuum dryer was able to dried Potassium carbonate for a single batch only. On the basis of R&D trials, the Unit has reduced the Potassium Carbonate to Sodium metal ratio from 10:1 to 6:1 and consumption from 500 kg per batch to 300 kg per batch. After reducing 65

8 the consumption of Potassium Carbonate, the Units is now able to dry potassium carbonate in Rotary vacuum dryer for two batches in a single batch time by utilize full capacity of dryer. Electrical Energy saving : 0.4 million kwh/annum Total in saving : 2.8 million Payback period : 0.17 year 3. Re-Engineering of process parameter to increase the recovery of Potassium carbonate in Iso butyl benzene (IBB) plant. In old process, recovery of potassium carbonate was done in the crystallizers at normal pressure. With the help of simulation software, the Unit analysed operating conditions, i.e. in between normal pressure v/s under vacuum to improve the recovery of potassium carbonate and generated the data. Result of analysis shows that the recovery of potassium carbonate gets increased with reducing the operating pressure of crystallizer. With the help of R&D data, the Unit implemented the revised operating parameters into the plant. Now, by applying vacuum in the crystallizer the quantity of mother liquor gets reduces which ultimately increase the recovery of potassium carbonate. Hence the yield of potassium carbonate increases. Electrical Energy saving : 0.5 million kwh/annum Steam saving : 2000 MT/Annum Total in saving : 6.9 million Payback period : 0.02 year 4. Optimization of Mono Chloro Acetic Acid (MCA) Plant process parameter to reduce the steam and power load on Utility On the basis of in house R&D center for optimization of the operating parameters of Acetyl chloride column and chlorinator reactor, pressure of chlorinator reactor was reduced from 3.5 kg/cm 2 to 2 kg/cm 2 and Acetyl chloride column pressure reduced from 0.8 kg/cm 2 to 0.25 kg/cm 2 which ultimately reduced the consumption of steam and also reducing the load on utility in the system. By reducing the pressure of steam and improving the efficiency of reboiler of acetyl chloride distillation column. Electrical Energy saving : 0.6 million kwh/annum Steam Saving : 1000 MT/Annum Total in saving : 5.9 million Payback period : 0.05 year 66

9 5. Isolate the one stage of steam jet ejector by installation of Flash Tank. In Monochloro Acetic Acid (MCA) plant, MCA distillation column operates under vacuum. The vacuum is generated with the help of three steam jet ejectors. In the modified system, the Unit installed a flash tank in the fresh feed to the distillation column so that all the non-condensable gases can be separated out and send to the three stage acetyl chloride reactors and which will reduce the load on steam jet ejectors. By reducing the load, one stage of the steam jet ejector was reduced resulting in save the steam and CT water consumption. Steam Saving Total in saving Payback period : 4000 MT/Annum : 6.8 million : 0.07 year 6. Using flash steam of condensate tank in acetyl column feed Flash Steam Generated from the steam condensate is being used in the acetyl distillation column of MCA plant. By the use of flash steam, thermal energy is saved. Steam Saving Total in saving Payback period : 5000 MT/Annum : 8.5 million : 0.01 year Energy Conservation Commitment Energy conservation continuous to be an area of major emphasis for IOL chemicals & pharmaceuticals limited. Unit has been continuously putting efforts to reduce specific energy consumption by both improving the technology and energy efficiencies. 67