Presentation for - CIIGBCgreenbusinesscentre.com/energyaward2017presentations/General... · Founder...

Team:

Mr. Shreedatta Albur

Mr. Shantanu S. Das

Ms. Shrutika Agrawal

Presentation for

CONTENTS

Introduction

Company and Site Overview

Energy Management

Energy management policy

Certification and benchmarking

Monitoring and Reporting Systems

Energy management plan

Energy Management Structure

Achievements

Savings in last 3 years

Major Energy Saving Projects

Energy Index Trends

Rewards & Recognition

Environmental Projects

Future Path© Reliance Industries Ltd., 2017

Dhirubhai H. AmbaniFounder Chairman Reliance Group

• 1966- Establishes Textile mill in Naroda

• 1977- Public share offering Raised money from

public offerings oversubscribed 7X

• 1982- Builds fiber/filament plant in Patalganga

• 1995- Builds Polyolefin plants at Hazira

• 1997- Builds multi-feed cracker at Hazira

• 1999- Builds Jamnagar refinery

• 2002- Acquired IPCL a state run company

• 2008- Builds JERP refinery at Jamnagar

• 2009- Begins KG D6 gas production

• 2013- Builds PBR/SBR plants at Hazira

• 2014- Builds PTA plant at Dahej

• 2014- Builds PET plant at Dahej

• 2016: Builds Ethane Tank, CCPP, JIO

RIL - BRIEF INTRODUCTION

© Reliance Industries Ltd., 2017

SUCCESSFUL BACKWARD INTEGRATION FOR FEEDSTOCK SECURITY IN PET & POLYESTER PRODUCTION


DMD Vision, Mission & Values

VisionThrough sustainable measures, create value for the nation, enhance

quality of life across the entire socio-economic spectrum and helpspearhead India as a global leader in the

domains where we operate.

Mission Values

Create value for all stakeholdersGrow through innovationLead in good governance practicesUse sustainability to drive productdevelopment and enhanceoperational efficienciesEnsure energy security of thenationFoster rural prosperity

Customer value

Ownership mindset

Respect

Integrity

One team

Excellence

product-wise breakup of the production figures


DMD Integrated Operation

Salt

Ethylene from VMD

Semi-Rich

Gas from

GAIL-

Gandhar

& Hazira

Gas Cracker

Plant

REON

EO

Raw Material

C2C3

EPRU

Cl2

VCM Plant

PVC Plant

Chlor-Alkali

Plant

C2H4

HDPE Plant

RELENE

MEG

CAUSTIC SODA

LYE

PROPYLENE

Plants

Imported

Propane &

Ethane

Lean

Gas to GAIL

Products

PET PRODUCT

EO-EG Plant

MEG

Para xylene

Acetic Acid

PTA

CPP

PTA

PLANT

PET Plant

BY-PRODUCTS


Energy Management Policy



Certification & Benchmarking

IMS Standards (since 2006)

Certification valid up to System

ISO 9001 – 2008 22, May, 2018 Quality Management System

ISO 14001 – 2004 22, May, 2018 Environmental Management System

OHSAS 18001 - 2007 22, May, 2018 Occupational Health and Safety Management System

ISO50001: 2011 Under Progress Energy Management System

Plant Year Benchmarking done by Level

GCU 2015 Solomon, USA Global

CPP & Utilities 2015 Internal Internal

HDPE 2015 Phillip Townsend Associates Global

PVC 2015 PDC Netherlands Global

Monitoring & Reporting SystemH

OU

RL

Y MIIS Energy Dashboard-Real time values of Energy KPIs

On-line monitoring tool IP-21 (Aspen Plus) for power, steam and fuel consumption

DA

ILY

Daily Site Energy Report highlighting the energy consumption pattern

Daily EIV report: Energy Influencing Variables that directly have an impact on the key performance indicators

MO

NT

HL

Y Site Monthly energy report to bring out salient points related to energy consumption and conservation

EPN VC: Energy Professionals Network involving Inter-site Energy cell members and Corporate energy cell



Energy Management Plan

• Review Results• Verify

Effectiveness• Examine

Opportunities• For Continual

Improvement

• Correct Deficiencies

• Review Objectives & targets

• Review Energy Program

• Update Action Plan• Set New Targets

• Implement Project• Monitor Progress• Lock In The Gains• Communicate

results

• Obtain Insight• Nominate

Energy Champion

• Develop Programs

• Set Targets & Measures

• Develop Action Plan

PLAN DO

CHECKACT

Employees Involvement

Major Function :

Set Targets

Provide direction

Benchmarking & External Audits

Review Utilityconsumption trend

Review status of ENCON schemes and PAT

Major Function :

Evaluation ofsuggestion scheme

Monitoring SpecificUtility Consumption

Conceive new and implement schemes

Optimize utilities Consumption

Major Function :

Identification ofscheme

Brainstorming

Suggestion Scheme

Employee & Vendor Involvement

AwarenessProgrammes


Quiz

Spot the energy losses,

Leaflet distribution

&

Drawing competitions for

children

Awareness sessions

Slogan and poster

competitions

ENCON Fortnight celebration . . .

Energy

related

Sessions by

eminent

scholar

Best ENCON Project


Year No of projects

No of Projects

with Zero Investment

Approx. Investment made

(Rs. Cr)

Savings achieved Approx.

(Rs. Cr)

Payback Approx.

(Months)

2014-15 8 5 6 403 0.2

2015-16 9 5 6 29 3

2016-17 5 1 6 9 8

Total 22 9 18 441 5

Savings In Last Three Years

CO2 emission reduction achieved through various schemes in last

year is approx. 8461 MT

Eleven Schemes were with zero investment with savings

of approx. Rs. 42 Cr


In GCU plant, Condensate stripper, C-1 is used for removal of C2’s and lighters condensing in C.G. 4th stage suction drum, V-5

Overhead stream goes to C.G suction drum, V-3. Remaining heavy components are sent to Gasoline Fractionator column from C-1 bottom

Due to high feed as compared to design flow, column operation is difficult and ineffective in stripping lighters

Column bottoms are flashed in V-6 for recovery of C4’s back to CG 1st stage suction. During flashing, C5+ also gets recycled resulting in higher CGC power

Incomplete separation results in C4 loss in gasoline product (RARFS).

1. Revamp of condensate stripper



Old scheme



Analysis and Development of Solution:

Increase in column stripping section diameter for higher feed flow rate

Stripping section converted to packed bed from old ripple trays

Reboilers and Column Bottom pumps replaced with high capacity ones

Reboiler condensate pumps replaced due to frequent maintenance issue and high

capacity

Effective stripping enhanced as the stripper overhead diverted to V-1, thereby

decreasing column operating pressure from 6.5-7 to 1.7 kg/cm2g.

XV provided at column top to avoid pressure increase beyond 2.5kg/cm2g

The column is diverted directly to G.F. column instead of first flashing into G.F.

feed K.O. drum via G.F feed heater and then going to G.F. column© Reliance Industries Ltd., 2017


Proposed scheme



Effectiveness

Power saving in Cracked Gas Compressor: Around 0.3 MWh

VHP saving in Cracked Gas Compressor: Around 1 MT/hr

MP Steam saving from reduction in GF reboiler duty: Around 1 MT/hr

LP steam saving in Condensate stripper reboiler: Around 0.3 MT/hr

Total monetary savings: Around Rs 4 Crs/yr

Reduction in CO2 emissions due to project implementation: Around

0.5 TCO2e per hour


2. Installation of Hydraulic Turbine

Problem Encountered:

Hydraulic energy loss from the solvent contactor to be recovered by using

hydraulic power recovery turbine

Existing pressure reducing valve can be eliminated

The energy saving is around 60 % of present energy consumed by the HT

motors of the amine circulation pumps

The required solvent flow & pressure differential in Rich solvent is enough to

provide the driving force for the Hydraulic Turbine




New Hydraulic turbine installation in solvent circuit.

Existing motor to be replaced with double shaft extension motor so that hydraulic

turbine can be installed.

Piping modification to route the rich solvent through the hydraulic turbine to

solvent flash drum.

A secondary level control valve at the inlet of the HPRT will be installed with

minimum pressure drop.

The control loop will be modified, so that the second level control valve operates

on a split range basis and in parallel with the existing LCV.



Effectiveness

Based on Around 500 m3/hr amine flow 359 kWh savings was achieved.

Total monetary savings: Around Rs 15 lakhs/yr

Reduction in CO2 emissions due to project implementation: Around 0.02

TCO2e per hour.


3. Interconnection of HP and LP air headers

Problem Encountered:

To reduce venting of air through UCV of both LP & HP air compressor.

Around 11500 NM3/hr. compressed air being vented.

Due to difference between minimum generation capacity & actual consumption

pattern of individual system.




Minimize the difference between minimum generation capacity & consumption by

interconnecting LP & HP stream air system

Other solutions that were already implemented are:

Reduction of minimum ampere set value of LP air compressors - reduced

venting by around 915 Nm3/hr.

Optimization of operating pressure of LP compressor.

LP air charged into complex service air header at around 2500 Nm3/hr.

Reduction of minimum ampere set value of HP air compressors from -reduced

venting by around 500 Nm3/hr.

Supplying air for aeration in ETP @ around 1400 Nm3/hr.



K-1

K-3

K-2

K-4

V-2

V-1

V-1

V-2

PK-4

PK-3

PK-2

PK-1

8.2

kg/c

m2g

Inst. air

receiver

LP air

receiver

Inst. Air 6.75 kg/cm2g

Plant air 7.5 kg/cm2g

30

kg/c

m2

g

Complex air header

C--2A

V-002

V-5 V-3

To PTA

PET-3/ETP

03-A Air

drying

unit

03-B Air

drying

unit

7.6

kg/c

m2g

C-3A

35 kg/cm2g

Plant air to PET

6.6 kg/cm2g

LP air

C-1A

C-1B

C-1C 6.6

kg/c

m2

g

V-1

Inte

rcon

nec

tion

for

emer

gen

cyTO EXISTING

PLANTS

Existing

HP system

LP system

Existing Service air

Comp



Effectiveness

Interconnection of LP. & H.P air headers leading to stoppage of one LP air

compressor

Reduction in power consumption: Around 1 MWh/hr.

Total monetary savings: Around Rs. 3 Crs /yr.

Reduction in CO2 emissions due to project implementation: Around 0.5

TCO2e per hour


0.00

0.50

1.00

1.50

2.00

2.50

3.00

2013-14 2014-15 2015-16 2016-17

2.782.99

1.95

1.85

Energy Index

Energy Index

Energy & Co2 Index Of Complex

0.00

0.20

0.40

0.60

0.80

1.00

2013-14 2014-15 2015-16 2016-17

0.810.91

0.51

0.54

Carbon Index

Carbon Index


REWARDS & RECOGNITION

2007: Five Star Rating of BSC Audit

2003: ISO 9001:2000, ISO 14001:2004, OSHAS 18001:1900 Certification

2004: GAIL Award for Gas Conservation

2005: Three Star Rating of BSC Audit

2006: CII Award of Excellence in Energy Efficiency

2006: Certificate of merit by BEE

2008: CII Award of Excellence in Energy Management

2009: RBNQA Quality Award

2009: Greentech Safety Award

2009: Greentech Environment Excellence Award

2008: CII Award of Excellence in Water Management

2009: 4-star Rating in BSC Environment Audit

2010: CII Award of Excellence in Energy Management

2010: Greentech Training Excellence Gold Award

2010: National Award for Prevention of Pollution

2009: ASTD BEST Award

2010 National Energy Cons. Award from Min. of power, GOI

2011 Greentech Training Excellence GOLD Award

2011 Four QC Excl. awards nat. convention on Quality concepts

2011 Four QC Gold awards State convention on Quality concepts

2012 Greentech Environment Excellence Award

2014 Greentech Environment Excellence Award

2015 CII Excellent Energy Efficient Unit award

2015 5th Greentech CSR Award

2015 National Energy conservation Award-Second prize

2016 CII Excellent Energy Efficient Unit award

2016 National Energy conservation Award-Certificate of Merit


Caustic chlorine plant of DMD is Notified as Designated Industry by Ministry of Power under PAT notification

In assessment year 2014-15 of PAT cycle-1, we have achieved SEC of 0.242 which was 16.84% reduction.

To receive and trade 8520 E-Certs from BEE, Ministry of Power

In PAT cycle-2, target given is 5.4% reduction of SEC

DMD, a cracker-based petrochemical site is one of the 4 RIL sites that is going to be included in the petrochemical sector of the PAT cycle-4

PAT


With 3 wind farms (61 Windmills) having a total installed capacity of

11.575 MW, generated 20129 MWH from 2014 to 2017.

Bio gas plant with an installed capacity of 600 kg/day of canteen is

in its final implementation phase.

Bio gas generated from anaerobic treatment in New ETP plant is

utilized in PET plant vaporizers.

Bio gas generated from the ETP plant is also used in sludge drying

process which in turn is used as a fuel in the Coal based power plant

as a substitute to coal.

Use Of Renewable Energy


RARFS vapour recovery unit in loading area to avoid emission of Benzene

that leading to Health hazard with an investment of 5 Crs.

Connectivity of Online Continuous Emission Monitoring system for stacks

with CPCB

Motor Operated Sluice Gates were successfully commissioned at both

MG-1 & MG-3 Storm water Mega channel.

New Bore Well for Ground Water Monitoring commissioned near Watch

Tower No. 4. Identification boards installed for all 8 Ground Water

Monitoring bore wells.

Environmental Projects


CCA available valid till 2020

Total 7 Ambient Air Monitoring Stations and

1 Continuous Ambient Monitoring System (CAAQMS)

Monthly Stack Monitoring by GPCB approved agency

Publishing Corporate Sustainability Report since 2004-05as per GRI guidelines.

“State of Art” Effluent Treatment Plant with Tertiarytreatment with a recycling capacity of 60%

Treated effluent from ETP is discharged in the Gulf ofKhambhat at a location recommended by NIO after due-diligence at 2.9 km deep inside the sea

Environment Sub Committee constituted for tracking andimproving Environmental Performance

System of 1st, 2nd and 3rd party Audits in place

Environmental Excellence


Use of Cooling tower blow down as a make up for fire water

Use of Gas Cracker off gas & EPRU flash gas as a fuel in captive power

plant boilers

Use of stripper off-gas as a fuel in Dow vaporizer in PET plant

Use of Hydrogen from Chlor Alkali plant as a fuel

Use of cooling tower blowdown for Horticulture resulted in annual

water savings

Resource Conservation


ECO POND FOR MIGRATORY BIRDS

Environment friendly


Our Distinguished Visitors – With

No Security Pass


Approach to EnCON

Systematic Approach :

Technically Steam, water management at site is in association with differentvendors

Daily reporting and monitoring by site engineer & CTS in charge

Monthly review meetings with Apex Committee & Corporate Energy cell

Brainstorming sessions through PFD reviews for continual growth

Rewards & recognition schemes to appreciate vendors performance during Energyfortnight celebration

Open forums for putting up innovative ideas with respect to ENCON likeMISSION KURUKSHETRA

Schemes Evolved:

Roll out of MIIS Dashboard

Application of aerogel insulation on VHP steam line

Daily use of Utility optimizer

Refurbishment of Cooling water pumps

Thermodynamic efficiency evaluation of pumps© Reliance Industries Ltd., 2017

Energy Savings Via IMS

There were no observations related to Energy in IMS audit conducted in 2016-17. Some observations pertaining to Environment are listed:

Observation Standard Corrective action

Requirement - Organization shall periodically test the procedures defined for responding to emergency situations which have impact on environment

ISO 14001:2004 Environmental impacts have been included in existing Mock drill format as control and mitigation points under "Containment", "Evacuation of spilled product" & "Cleanup & disposal of waste".


Projects Underway 2017-18

S No PROJECTS1 CT 02 & CT 03 pump efficiency improvement

2 Recovery of steam condensate of secondary brine used for brine heating

3 Interchange heat between High temperature HP condensate and low temperature BFW

4 Energy saving potential by replacement of existing HPMV, HPSV & Flood Light fixtures by LED

5 Replacing the Chilled water pump by New Energy Efficient Pump

6 Replacing EOEG HP steam with site MP steam in MEG drying column reboiler.

7 Partially replacing EOEG MP Steam by introducing a new LP steam heat exchanger, and reduce MP steam consumption.

8 Close loop condensate system for VCM Plant


Further Information please contactShreedatta albur–[email protected] S Das [email protected]

Shrutika Agrawal [email protected]© Reliance Industries Ltd., 2017

mailto:albur–[email protected]



mailto:[email protected]

mailto:[email protected]

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