190

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 1989. 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 2012-13 2013-14

Ethylene + Propylene 560 78 79

EO+MEG 81 91 114

LDPE 110 102 90

LLDPE/HDPE 240 80 96

PP 120 86 85

BUTENE-1 15 0 0

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

191

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 50001 certification received in the year 2013. Group of engineers have

been trained and certified as ISO 50001 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.

192

Energy Policy

193

Certificate of Merit

Petrochemicals

PANIPAT NAPHTHA CRACKER

Panipat (Haryana)

Unit Profile

Panipat Naphtha Cracker, the largest Naphtha Cracker in India, was commissioned

in March 2010. 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 2012-13 2013-14

Naphtha Cracker Unit 113 109

Poly Propylene 331 320

SWING 196 196

High Density Polyethylene 502 468

Mono Ethylene Glycol 338 338

194

Specific Thermal Energy Consumption in M kCal/Ton of Product

Units 2012-13 2013-14

Naphtha Cracker Unit 4.9 4.7

Poly Propylene 0.3 0.3

SWING 1.2 1.2

High Density Polyethylene 0.3 0.3

Mono Ethylene Glycol 1.2 1.1

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. 1.72 Lakh.

Electricity saving : 0.41 Lakh kWh.

0

100

200

300

400

500

600

Naphtha Cracker

Unit

Poly Propylene SWING High Density

PolyEthylene

Mono Ethylene

Glycol

Specific Electrical Energy Consumption in

KWHr/Ton of Product 2012-13

Specific Electrical Energy Consumption in

KWHr/Ton of Product 2013-14

0.00.51.01.52.02.53.03.54.04.55.05.5

Naphtha

Cracker Unit

Poly Propylene SWING High Density

PolyEthylene

Mono Ethylene

Glycol

Specific Thermal Energy Consumption

Million kCal/ tonne 2012-13

Specific Thermal Energy Consumption

Million kCal/ tonne 2013-14

195

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. 1.55 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. 1.69 Cr./year. The issue of Slop Oil

disposal has also been resolved effectively.

Investment : Rs. 7.61 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 600-700 kWh

(Both lines total).

Investment : Nil

Electricity saving : 30.66 Lakh KWh.

196

Energy Policy

197

Certificate of Merit

Petrochemicals

ASIAN PAINTS

PHTHALIC DIVISION Ankleshwar (Gujarat)

Unit Profile

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 1990. 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.

198

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 m3/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 1990-2000 2000-till date

Steam consumption, kg/hr 9000 9000

Specific consumption, kg/kW 8.5 7.1

Power generated, kW 1058 1267

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

m3/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

199

270 °C. This scheme has reduced the natural gas consumption from 3500 m3/day to

2000 m3/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 2010-11 & 2012-13 were catalyst replacement year.

Normal capacity operation years are non-catalyst replacement years i.e. 2009-10,

2011-12 & 2013-14.

0.000

0.020

0.040

0.060

0.080

0.100

2009-10 2010-11 2011-12 2012-13 2013-14

Specific Energy Consumption

TOE / MT

1100

1120

1140

1160

1180

1200

1220

1240

1260

1280

1300

APR MAY JUNE JUL AUG SEP OCT NOV DEC JAN FEB MAR

Plant load (KW) 2013-14

Modification

in Ilexan

system - 10

New AIS

Blower with

VFD , Saving-

5.5 KW

Plant air

compressor

replaced with

screw - comp. -

30 KW

Reduction by 30%

wrt year 2009-10

200

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 2009-10. Current level of

specific natural gas consumption is 46% lower than year 2009-10.

II. Effective reduction in energy consumption, both, in absolute terms of inputs for given unit of output & overall saving realized qualitatively and quantitatively.

Year

Specific

consumption

Sp. Natural gas

consumption

TOE / MT SM3/MT

2009-10 0.052 54.19

2010-11 0.062 62.04

2011-12 0.050 53.13

2012-13 0.077 68.74

2013-14 0.036 39.20

Major Energy conservation projects

Year Actions Effect

2013-14 Replacement of plant air compressor 34 kW power saving

Modification of Ilexan hot oil circulation

system

10 kW power saving

Replacement of pumps and motor with energy efficient equipment (Turbine cw pump, cold oil pump-2)

12 kW power saving

Process flow control through VFD (Therminol circulation pump, HP BFW

11 kW power saving

82032

93165

105732

114199

106334

9174588810

77515

62289

5724251711

62050

50000

60000

70000

80000

90000

100000

110000

120000

N. Gas Consumption

201

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 sm3/day natural gas

III. Greenhouse Gas inventorization and changes in last 2/3 years

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 Unit of measure

Design Parameters

Current Parameters

1.

Specific power

consumption from external sources

Units / MT 31 0.0

2. Specific fuel consumption for

thermic fluid heaters

Kg / MT 85 29

0

500

1000

1500

2000

2500

3000

3500

4000

4500

2009-10 2010-11 2011-12 2012-13 2013-14

Total Equiavalent CO2 Emmision

(in MT / annum)

Reduction by

923 MT wrt

As per US EPA calculation