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 private sector enterprise, with businesses in the energy and materials value chain. Groups annual revenues are in excess of US$ 58 billion. The flagship company, Reliance Industries Limited, is a Fortune Global 500 company and is the largest private sector company in India. Reliance Industries Limited -Vadodara Manufacturing Division (RIL-VMD) is the oldest complex in the Reliance family. RIL-VMD (Erstwhile Indian Petrochemicals Corp. Ltd.), the pioneering petrochemical unit in India, was incorporated in March 1969, as a Government of India Enterprise to catalyze growth of Petrochemical Industry. RIL-VMD was the worlds largest integrated petrochemicals complex with multi-product manufacturing portfolio which included Polymers, Synthetic Rubber, Fiber Intermediates, Solvents and Industrial Chemicals when it was commissioned. In line with the Companys vision, RIL-VMD focuses on achieving excellence in production, safety, environment & corporate social responsibility. Company has a strong Energy policy on Energy conservation and environment protection which strives to: Reinforce a culture for persistent exploration of possibilities for minimizing energy throughput across any system and thereby achieve reduction in production cost as well as enhancing environment quality. Create awareness and alert response to energy conservation movement among the employees, their families and society; thereby evolve a critical mass of people with shared value for energy conservation. 393
Energy Strategy: RIL - VMD has adopted Energy Conservation as its corporate business strategy. It has well established systems that ensure energy conservation as per the objectives set in all the units. A dedicated Energy Cell (Energy Dept) is in place which carries out following activities: Retrofitting and modifications with a view of making vintage technologies more efficient. Technological change to adopt energy efficient processes. Benchmarking study to develop energy roadmap is done with different RIL sites for gap assessment and corrective actions implementations. Implementation of energy management system is in place and was awarded ISO 50001:2011 certification in July -2015. Application of software tools for Heat integration study and utility optimization is in place, which helps evaluate energy conservation schemes, before the schemes are put in place. Awareness through training and Idea generation at unit level is done regularly. A system is in place, where employees can put ideas in to the system, which are evaluated by energy cell. Application of best energy practices across the globe by engaging different consultants. Monitoring energy consumption (online Energy dash board) for identifying and correcting thrust areas. Energy performance: 394
Projects implemented in 2015-16 Various Energy conservation projects were taken up during 2015-16, major projects are: Project 1: Cracker convection coil internal cleaning by pigging method Naphtha cracking heaters have a coke deposition and needs to clean based on its run length once stack temperature increases. All the row of convection bank has finned tubes, except first 4 rows in mix preheat section. In the past, external cleaning of convection bank was done with dry ice but limited gain was achieved. With Pigging method, internal cleaning of lines were carried out which couldnt be cleaned normally by other means, which resulted in saving of fuel gas due to increased heat recovery in convection section. Challenges faced DURING project. Tubes cleaning by larger diameter tubes is quite prevalent in oil industries, but pigging in small diameter pipes (As small as 2" dia) is seldom tried. Project 2: Installation of high efficiency cooling water pumps Cooling water pumps were operational in GOP Tower since commissioning. Even after pump refurbishment the efficiency never improved above 75% (Design-85%) that resulted in reduction in total circulation flow and adversely affecting refrigeration system. Installation of high efficiency, higher head cooling water pumps has helped to optimize CW circulation flow rate and reduced power consumption in cooling water pump Challenges faced DURING project. Major challenge was installation of pump without plant shutdown. With utmost safety one by one pump installation with the help of scuba diver. Other challenges were alignment of old motor on same foundation Project 3: Installation of new footprint turbine for CGC and C3R Charge Gas Compressor and Propylene refrigeration compressor turbines were of old design installed in 1978. Over the time specific steam consumption of turbine increased for CGC turbine and C3R turbine, which has been replaced by high efficiency. Since the new turbine has been installed on the same footprint of old ones, it helped to minimize changes in the steam line and oil circuits. Throughput limit, especially during summer condition, was observed due to limitation in C3R turbine, which has been overcome. Challenges faced DURING project. Major challenges were alignment of turbine inlet steam line & extraction line & achieve required oil quality of control oil. The cracker shutdown period is always 395
limited in view of economics and installation of new turbine is next to impossible during the outage. Concept of footprint turbine has helped to install and commission within available shutdown period. Project 4: Flare Tip Replacement by High energy efficient flare tip GOP flare tip was an old design tip (1970s design). A new high efficiency flare tip was installed during the complex turnaround in February 2016 with special designed steam spargers and pilot to reduce the steam and fuel gas required for combustion of flared gases. The high efficiency flare tip is also designed to ensure complete combustion and hence smokeless flaring at current flaring loads. Challenges faced DURING project. Major challenges during the installation of the new flare tip was installation of the flare tip and inspection of the molecular sieve at the flare stack height of 120 m from ground level. This was a high risk job and was carried out safely. Project 5: Heat integration for preheating the feed at PBR1: PBR 1 plant is a high energy consuming plant. In one of the column feed is preheated using MP steam. During heat integration study, an opportunity was identified to reduce this steam consumption by preheating the column feed with downstream column overhead vapors Challenges faced DURING project. The possibility of two phase flow and flexibility during startup and commissioning of the scheme one of the challenge. List of Major Energy Conservation projects in 2015-16: 396
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Second Prize Petrochemicals RELIANCE INDUSTRIES LIMITED NAGOTHANE MANUFACTURING DIVISION Raigad District (Maharashtra) Company Profile Reliance Industries Limited (RIL) is Indias largest private sector enterprise having a modest beginning in the 1960s with a textile firm. It embarked on a journey of continual backward integration and has now established its presence in polyester, fiber intermediates, plastics, petrochemicals, petroleum refining, oil & gas exploration, Life science, retail and telecommunication. RIL is the first Indian private sector company to feature in The Fortune global 500 list of the Worlds largest corporation for 11 consecutive years with position of 158 by total revenue in 2015-16. RIL is rated as the 15th Most Innovative. Indias greenest and most environment-friendly company, ranking 185th among the worlds largest 500 companies, according to Newsweeks Green Rankings 2014. RIL today is a conglomerate with one of the most complex petrochemical value chains in the world. RIL contributes approximately 20% of Indias total exports Nagothane Manufacturing Division (NMD) Nagothane Manufacturing Division (abbreviated as RIL- NMD) is a petrochemical site and is one of the 6 major petrochemicals manufacturing sites of RIL. NMD is located in the Raigad district of Maharashtra. It was commissioned as part of the IPCL site in 1989. IPCL was acquired by RIL in 2002. Since 2002, NMD is part of RIL which is a public limited company. NMD complex comprises of a Gas cracker plant with the main feedstock as Ethane and Propane mix from ONGC and imported Propane. The downstream to this unit are the plants producing high quality grades of Polyethylene, Polypropylene and chemicals like EO and MEG. RIL-NMD also has a plastic recycling unit, RPET. Relative importance of offered products depends on the changing market demand. It is our constant endeavor to develop products that provide world-class experience to our customers across a range of applications packaging, agriculture, automotive, housing, and healthcare among others NMD has 85 MW Captive power cogeneration plant and Heat Recovery Steam Generator Boilers of 136 TPH capacity each for steam generation of 105 kg/cm2 and 5100C. 398
NMD employs world class technologies and the quality of products match international standards. All polymer products are covered under FDA. NMD produces about 600,000 TPA of Polymers and Chemicals for dispatch. Production Capacity Product Installed Capacity Utilization Capacity in % KTA 2014-15 2015-16 Ethylene + Propylene 560 73 94 EO+MEG 55 109 177 LDPE 80 119 143 LLDPE/HDPE 220 84 109 PP 120 85 98 Energy Consumption: Energy requirement of the complex is met by captive generation of steam & power in Captive Power Plant (CPP). Captive Power Plant (CPP) meets the power and steam requirement of the entire petrochemical complex under continuous, start-up and emergency cases. CPP has the following generating assets - 3 Gas Turbine Generators (GTG), 22 MW each. (2 GTGs are uprated to 22 MW each) - 3 Heat Recovery Steam Generators (HRSG) of capacity 136 TPH each. - 1 Steam Turbine Generator (STG), 25 MW In normal operation, 2 Gas Turbines, 2 HRSG and 1 STG will be in operation to cater the complex power and steam demand. GT operates on Lean Gas and Fuel Gas firing and HRSGs operates on GTG Exhaust gas and Cracker Generated Fuel Gas. CPP imports power from MSEDCL (Maharashtra State Electricity Distribution Company Limited) distribution grid as per operation philosophy. Energy Index for last four years: 399
Energy Conservation Achievements List of Energy Conservation Projects implemented during 2015-16 Sl Year of Title of Energy Achievement of Annual Energy No Implemen Saving project Savings in 2015-16 tation implemented Electricity Fuels Lakh KWh Coal F.Oil Lean Gas Total (tons) (KL) (Tons of (MTOE) Fuel) 1 Gas Turbine uprate 2546 2804 2 Use of available chilling capacity from LDPE VAR to LLD AHUs 7 60 3 150W HPSV street lights by 90W LED lights 0.01 0.08 4 Provision of HP residue gas line to HP knock out drum for GTG fuel 5689 6266 5 2015-16 VAR machine temperature control in EOEG 48 53 6 Reduction in steam consumption by de-rating HP steam control valve 300 331 7 Stoppage of VAR in DHC and use of AC in laboratory 103 114 8 Increasing steam insulation thickness based on fuel prices 80 88 9 Demo furnace convection section dry Ice blasting 52 57 Sub Total 7.01 8818 9773 * Tons of fuel saved is based on Lean Gas equivalent with net calorific value of 11,015 KCal/Kg 400
Certificate of Merit Petrochemicals RELIANCE INDUSTRIES LTD - DAHEJ MANUFACTURING DIVISION Distt. - Bharuch (Gujarat) Unit Profile Dahej Manufacturing Division (DMD), an integrated petrochemical complex located near Jageshwar Village, Bharuch District, Gujarat, 130 Kilometers southwest of Vadodara which earlier known as Indian Petrochemical Corporation Limited established in 1969 merged with Reliance Industries Limited since October 2007. The site is in the vicinity of the Narmada estuary and seven kilometers from the Dahej port. RILDMD produces main products namely Polyvinyl Chloride (PVC), High Density Poly Ethylene (HDPE), Mono Ethylene Glycol (MEG), Caustic soda lye & Ethylene Vinyl Acetate (EVA), Polyethylene Terephthalate (PET) & Purified Terephthalic Acid (PTA) along with some valuable chemical by products like HCl, Wax, DEG, TEG, Mix Oil, RARFS etc, which are either consumed internally, exported 401
to sister divisions or sold in the open market. Propylene produced in Gas Cracker Plant of DMD, which is a raw material for manufacture of PP Polymer, is exported to VMD where it has PP manufacturing Plant through connected piping network. Energy Consumption: Sustained effort of Dahej Manufacturing Division, over the years, to reduce energy consumption in its energy intensive petrochemical operations has resulted into 35.31 % reduction in Overall Specific Energy consumption reduction over last 2 years. With the implementation of various energy conservation measures as ongoing practice, there is steady decline of 33.84% & 22.07% specific Electrical and Thermal energy consumption respectively. Last two years specific energy consumption figures are shown below, which depicts continual reduction in energy consumption. Description Unit 2014-15 2015-16 % Reduction Specific Electrical Energy Kwh/MT 541 358 33.84 Specific Thermal Energy Gcal/MT 1.53 1.20 22.07 Total Specific Energy consumption Gcal/MT 3.01 1.95 35.31 402
Energy Conservation Achievements: In 2015-16, unit had implemented 8 nos of energy savings projects which have reduced energy consumption of site considerably. Annual savings of Rs. 2468 lakhs was achieved with as investment of Rs. 613 lakhs with a payback period of approx. 3 months summarized in below table 403
Energy Policy: 404