Thirumalai Chemicals Ltd.,RanipetThirumalai Chemicals Ltd.,Thirumalai Chemicals Ltd.,RanipetRanipet

1

Thirumalai Chemicals LtdRanipet, India

History of Thirumalai Chemicals Limited ……

Public limited Company

Started in the Year 1973

Sales Turnover Rs.400 crores

Global Leader for all products

TCL – India & TCL – Malaysia together has the largest capacity in the

world to produce Maleic Anhydride

Our products & Applications

Phthalic Anhydride – 87, 000 Tons / Year

Paints

Polyester Resins

Plasticizers

Maleic Anhydride – 17, 750 Tons / Year

Paints

Pharmaceuticals

Polyester Resins

Malic AcidFood Acids – 17, 000 Tons/Year

Soft Drinks

Candies

Pharmaceuticals

For Manufacturing Cheese

Fumaric AcidFood Acids – 17, 000 Tons/Year

Candies

Soft Drinks

Animal Feed

1973

1997-98

PA 6000 TPA

PA 19,000 TPA

PA 25,000 TPA

PAN 87,000 TPA

1974-76

1985-86

1988-89

1997-98

MA 1,000 TPA

MA 11,000 TPA

MA 17,750 TPA

1988-89

1990-91

FOOD ACIDS 1,000 TPA

1991-92

FOOD ACIDS 17,000 TPA

1997-98

Organizational Growth

ISO 9002

INEA

INEA – International Export Award

ISO 14001:1996

ISO 9001:2

000

ICMA Energy Award

HACCP

ISI Fumaric

Acid

ISO 14001: 2004

AWARDS AND MILESTONES…

1994

1995

2000

2001

2002

2003

2004

2006

Importance of Energy Management in TCL

Importance of Energy Management in TCL

TCL, being a Petro chemical Industry, is energy Intensive.

Energy cost contributes to about 3-4 % of the manufacturing costs and is next to raw material cost.

The increased competition and raising prices of Power & Fuel demands cost reduction in all respects for survival.

The prime focus is on Energy cost reduction through efficient waste heat recovery, conservation measures and productivity improvement.

The main emphasis is towards Generation, Distribution and Usage of Steam & Power as efficiently as possible.

Establishment of Energy Cell in TCL

Opportunities to implement energy conservation activities.

Formed a separate energy cell in the Year 2000.

Energy Cell comprises of an Energy Manager & Energy Engineer.

Activities of Energy Cell in TCL

Energy Cell’s main role is to Facilitate Energy Conservation activities to optimize Energy ConsumptionActivities:1. Data collection:

a. Steam generation & consumption

b. Power generation & consumption

c. Fuel consumption 2. Preparation of Steam & Power balance for entire network

3. Calculation of daily energy cost through a separate Energy Module for various products

4. Efficiency calculations of high energy generating equipments like Turbines, Turbo blowers & fired heaters.

Activities of Energy Cell in TCL Contd…

5. Analyzing & taking immediate Corrective actions for daily deviations

6. Monitoring of instrument air generation & consumption

7. Maintaining records for daily deviation to eliminate for future occurrences

8. Calculating daily losses (venting & failure losses)

ENCON Methodology

ENCON Methodology

Idea Generation

Audit &Monitoring

ImplementationFeasibilityStudy

From Energy Cell

From HODs,

Engineers &Supervisors

From TPM circles

Through Suggestions

By HODs or energy cell

Preparation of detailed report

( Investment, cost,benefit ,Payback etc)

Approvalby

Management

Implementation by

Concerned HODs

Report Generation after Completion

Audit by Energy cell

Report Generation On Actual saving & Expected Saving

Monthly Monitoringthe Performance

by Energy cell

Energy Conservation Activities Carried out

in Electrical Systems

1.Stoppage of unnecessary & Idle running drives

2. Conservation using V.F.D.

3. Power Reduction using Pulley Changing.

4. Capacitor provision to improve power factor

5. Frequency reduction in the generating point

6. Voltage Reduction in Feeder from 500V to 415V

7. Segregation of Low & High Head Cooling Water Pumps.

8. Installing Energy Efficiency Motor.

9. Energy efficient lamps

10. Providing LED Lamps for Panel Indication.

Energy Conservation Activities

Variable frequency drive - Speed Reduction

Downsizing the motors - Lower Capacity motor

Pulley size changing - Speed reduction of Drives

Energy Conservation in Cooling Water System

Various Power Reduction Activities

Case Study –

Energy conservation in Hot Oil Circulation Pump using VFD

I - VFD Installation in Hot Oil Pump (PA Plant)Before Condition:

∗ During re-cooling, hot oil is re-circulated bypassing SWC. Hence scope for Power reduction.

SWC-1 SWC-2 SWC-3 SWC-4 SWC-5

HOT OIL TANK

HOT OIL SYSTEM

Running amps : 24 ampsRunning Power : 17.0 KwFrequency : 50 Hertz

After Condition:∗ Power reduction can be achieved by reducing the speed by reducing the

frequency.

∗ Interlocked with the recycle valve.

∗ The flow at the reduced speed is sufficient to maintain the

hot oil temperature.

SWC-1 SWC-2 SWC-3 SWC-4 SWC-5

HOT OIL TANK

Running amps : 7.5 ampsRunning Power : 5.0 KwFrequency : 30 Hertz

VFD

MELTING CYCLE RECOOLING CYCLE

Running amps : 7.5 amps

Running Power : 5.0 Kw

Frequency : 30 Hertz

Power Savings : 12 KwHR = 0.288 Lakh kwh/Annum

RESULT

Running amps : 24 amps

Running Power : 17.0 Kw

Frequency : 50 Hertz

Energy management

Case Study

Elimination of Power Lossin MA plant

BEFORE

1440 RPM

37 KW

30-40 %

Oxidation temperedwater pump

Suction line

Speed 1440 rpm

Motor 37 KW

Discharge valve opening 30%-40%

AFTER

960 RPM

18.5 KW

70-80 %

Oxidation temperedwater pump

Suction line

Using VFD RPM reduced to 960

Satisfies the process requirements

Motor changed to 960 RPM

COST BENEFIT

Project costRs 0.5 Lakhs Saving / month

Rs 0.8 Lakhs

Pay back 20 days

Energy management

Case Study

Power Reduction in Blowers

(FUMARIC ACID PLANT)

AIR EXHAUST TO FINES RECOVERY SYSTEM

PREHEATING ZONE HEATING ZONE COOLING ZONE

15 BAR STEAM

AIR PREHEATER

DRYER BLOWER

COLD AIR DUCT

HOT AIR DUCT

PIN AGITATOR

WET MATERIAL INLET

AGITATOR

FUMARIC BED

150 deg C

Process of Fumaric Acid Drying

HIGHER CAPACITY OF BLOWER SPEED-1440 RPMDamper opening 30%

DAMPER

30 %OPEN

DRIER

PULLEY 310 mm

1440 rpm

BEFORE

DAMPER OPENING INCREASED TO 70% BY REDUCING THE SPEED TO 920 RPM BY CHANGING THE PULLEY SIZE TO 400 MM

DAMPER

70 %OPEN

DRIER

PULLEY 400 mm920 rpm

AFTER

Pulley (400 mm)

Blower

Motor

RESULTS

28

13

10

15

20

25

30

BEFORE AFTER

KW/hr

REDUCTION IN POWER CONSUMPTION

Good

BENEFIT

0

3.9

0

1

2

3

4

BEFORE AFTER

Lakhs/ Annum

GOOD

ROI

INVESTMENTRs. 0.05 LAKHS BENEFIT

Rs. 3.9 LAKHS

ENERGY MANAGEMENT

Case Study –

Energy conservation in Cooling water system

ANALYSIS

Three High capacity ( 90 kW ) Cooling water pumps are in operation for serving Two Turbo Blowers & one Turbine generator.

During Part load operation ( One TG & One Turbo blower ) all three high capacity pumps has to run.

No Low capacity pumps is available to satisfy part load operation

System studied and provided one low capacity 55 kW cooling water Pump.

High Power consumption in Utility cooling water system during part load

operation

BACKGROUND

KAIZENS

50 % OPEN

90 kW

90 kW

90 kW

To Turbo Blowers & Turbine

FULL OPEN

55kW

90 kW

To Turbo Blowers & Turbine

Before After

RESULTS

Power Consumption kW / hr

215

250

200

220

240

260

280

BEFORE AFTER

BENEFIT

0

15.12

0

2

4

6

8

10

12

14

16

BEFORE AFTER

Saving RS in lakhs / Year

Energy Conservation Activities Carried out

in Thermal Systems

Implementation of Co-Generation System

Introducing new Flash Drums

Insulation of Chimney- To Reduce Flue Gas Temperature from 220*C to 200*C

Increasing Productivity thereby increasing Steam Generation

Steam Trap Performance Checking using Ultra Probe-2000

Process Modification in Distillation Batches- Reduction in Steam Consumption

Optimizing Air PreHeater Steam Consumption.

Steam Leak Arresting using a separate Team

Energy Conservation Activities

Energy management

Case Study

Implementation of Co-Generation System

Co-generation system in TCL

Consumers

40 Bar(HPS)

40 Bar (HPSH)

15 Bar(MPSH)

Turbine

15 Bar (MPS)

DSH

Turbo Blowers

6 Bar Steam

4 Bar Steam

Consumers

Condensate

Superheater

6 Bar Flash Drum

4 Bar Flash Drum

Boiler feedwater Tank

Condensate

Condensate

4 Bar from DistillationCondenser

Contd…

Heat Recovery Unit of Reactors

Our processes are designed to utilise all heat liberated from exothermic reaction

Generation of high pressure steam (40 bar)

Meets both Process heating & Power requirements

Our process requires steam at various Pressures.

Installed a 5 MW Turbo generator (Extraction cum Condensing )

The extraction steam meets process requirements.

Co-generation system Contd…

Best Practices in Co-generation systemContd…

Generation of 4 bar steam from distillation condenser

Recovery of 4 bar steam from Medium pressure condensate, through flash drum

4 bar steam is used for process heating

All the steam condensate after heat recovery is diverted to Boiler feed water tank in order to utilize the sensible heat.

Steam driven Turbo blowers meet our process air requirement Medium pressure flash drums in condensate network, to recover

. steam at 6 bar.

Implementation of New HP Flash Drum

Case Study

Energy conservation in Steam Network

BACKGROUND

Generation of 4bar Steam from 40bar,15 bar condensates.

Generation of 4 bar steam is in excess.

Venting of 4 bar steam.

ANALYSIS

In normal Plant operation,venting of 4 bar is resulted.

During the shutdown period of downstream plants,venting of 4bar steam is high.

6 bar demand for plant heating is met by letting down from 15bar to 6 bar .

So it is planned to flash 40,15bar condensates into a new Medium pressure flash drum to generate 6 bar steam.

4 Bar steam

Condensate

Condensate

6 BarFlash

Vessel

6 Bar steam

High PressureCondensate

Before:4 Bar Steam Vented to Atmosphere

After:6 Bar Flash Drum Introduced

Flash Vessel

High Pressure Condensate

Low Pressure Condensate

4 BarFlash Vessel

Low Pressure Condensate

4 Bar steam

Condensate

RESULTS• Venting of 4 bar steam is minimized

• Cost Saving is Rs.3.5lakhs/month.

• Horizontal Implementation in another Plant.

S a v in gR s 3 .5 L a k h s

I n v e s tm e n tR s 1 .0 0 L a k h s

BENEFIT

Extent of Team Work in ENCON Activities

Identifying / eliminating energy related abnormalities through O&M

Concept

Monitoring & taking corrective actions through Daily Work management

Concept of Small group activities has given a clear approach & idea on

loss elimination techniques

Most of the abnormalities like steam leaks,Instrument air leaks,

Condensate leaks are attended by Operators themselves

Contribution of Workmen / Supervisors

Steam traps inspection & skin temperature measurements are being carried

out by respective plant supervisors

Energy week & Suggestion scheme motivates our employees to give

innovative & creative suggestions

Every employee is involved in one or other of the energy conservation

activities implemented in his plant which gives them a sense of

accomplishment

Contribution of Workmen / Supervisors Contd..

Overall Results

2.00

1.46

1.101.01

1.16

0.63

0.00

1.00

2.00

3.00

2000-01 2001-02 2002-03 2003-04 2004-05 2005-06

MILLION K.cals / MTSpecific Energy Consumption

in Million K.cals / MT of Product

163.6

124.7

100.092

103

56

0

20

40

60

80

100

120

140

160

180

2000 -01 2001 -02 2002 -03 2003-04 2004-05 2005-06

LTS/ MT

Specific F.O Consumption (Lit/MT)

36.2

23.0

9

13

6

12.6

0

5

10

15

20

25

30

35

40

2000 -01 2001 -02 2002 -03 2003-04 2004-05 2005-06

LTS/ MT

Specific H.S.D Consumption (Lit/MT)

27

35

26

12

26

63

0

10

20

30

40

50

60

70

2000 -01 2001 -02 2002 -03 2003-04 2004-05 2005-06

KW/ MTSpecific Consumption - EB

12.7

11.411.6

10.9

8.6

6

7

8

9

10

11

12

13

14

2001-02 2002-2003 2003-2004 2004-2005 2005-2006

(KL/MT)

Specific Water Consumption (KL/MT)

Future Improvements

To eliminate 4 bar venting (excess) steam, Planned to install a new

boiler feed water preheater

Horizontal Implementation of High & Low Head Cooling Water

Segregation in another Plant.

Installation of new SBC to increase the productivity

Replacement of Electric heater with Steam heater in the Air

drier unit

Thank you