Sayantan Bhowmik Head Technology Rotary Cell Energy Manager

© Reliance Industries Ltd.

Sayantan Bhowmik

Head Technology Srinivas Wuriti

Energy Manager

Jeevan Jadhav

Section Head

Rotary Cell


RIL Profile

RIL

Turnover Rs 4,30,731 Crore

Net Profit Rs 36,075 Crore

Contribution to national exchequer Rs

86,942 Crore

Energy saved on account of conservation

initiatives (’000 GJ): 3004

Total water recycled (’000 m3): 69364

Source: Annual Report 2017-18

RIL-NMD

Turnover of Rs 5,420

Crore.

Energy cost is 24% of

Manufacturing cost.


RIL NMD Process

GAS CRACKER

MEG

59,000 TPA

EO

56,000TPA

POLYROPYLENE

1,20,000 TPA

LLDPE/HDPE

2,55,000 TPA

HEXENE-1

15,000 TPA

LDPE

112,000 TPA

RECYCLED PET

7,300 TPA

PROPYLENE

1,15,000TPA

ETHYLENE

4,40,000 TPA

PP

HEXENE-1

EOEG

LDPE

LLDPE/HDPE

RPET

C2C3

PROPANE

WASTE PET

Fully Integrated with value addition at each step


Sp. Energy Consumption in last 3 years

Continuous reduction in specific energy


Sp. Energy Consumption in last 3 years (Thermal)


Sp. Energy Consumption in last 3 years (Electrical)


Benchmarking Process


Benchmarking - Gas Cracker

Solomon Benchmarking (last in 2017) (Benchmarking done with world wide Cracker plants)

Energy performance

Actual specific energy consumption in year- 2017 was 17.5 GJ /ton of HVC Vs 16.8 GJ/ton of HPP plant - 2rd quartile.

Actual specific energy consumption in year- 2015 was 17.9 GJ /ton of HVC Vs 17 GJ/ton of HPP plant - 3rd quartile.

Based on 2015 results

Gap analysis done

and closed the gap of

0.4 GJ/ton by

efficiency

improvement of CG

and C2R turbines.


Benchmarking - PP

Spheripol Benchmarking by Lyondell Basell

NMD PP Global Average

Nameplate capacity utilization 151 % 120 %

Monomer specific consumption 1.006 t/t 1.007 t/t

Electricity specific consumption 256.4 kwh/t 311 kwh/t

Steam specific consumption 178.2 kwh/t 264 kwh/t

Nitrogen specific consumption 44.1 Nm3/t 42 Nm3/t

NMD PP is consistently better than global average in prime product %.

NMD PP continuously leverages the technology strength and focuses on

higher MFI Random Grades.

NMD PP achieved 89% Random Grade mix against the 13.4 % global

average.

PP participates in M/s Phillip Townsend benchmarking too

Europe--- 14 plants

Americas---15 plants

Far East---16 plants

Rest of world---10 plants


Benchmarking - CPP

CPP Gas turbine units are benchmarked internationally with Fleet data by M/s SPS

Inc. USA. ORAP (Operational Reliability & Availability Program) (Jan-Jun, 2015).

Availability Reliabili

ty

Service

Factor

MS5001 Fleet,

2015

99.7 99.8 62.3

Others 89.9 98.7 22.7

Fleet 90.2 98.8 23.9

Best in Globe among Frame V fleets.

Good GTG reliability which means fewer startup/shutdowns resulting in lower energy consumption in CPP and the complex.

More than average among all registered fleets for Frame 5 international bench marking.

Monthly inter site benchmarking: First rank amongst all RIL plants in 2017-18

Equipment Performance

Site Unit PMD HMD JMD-D VMD NMD DMD JMD-Z

GT/HRSG Co-gen efficiency % 66.17% 74.12% 84.33% 83.15% 80.55% 75.09% 82.32%

STG cycle efficiency % - 26.62% 40.32% - 38.47% 31.99% 72.60%

Aux boiler thermal efficiency % 92.20% - 92.00% 87.33% - 92.67% 95.42%

Overall fuel efficiency % 76.26% 66.08% 78.45% 80.63% 67.82% 53.55% 80.48%

Fuel eff. Improvement Index % 96.37% 98.27%

102.87

% 94.35% 111.86% 65.43% 100.70%


Implemented Projects Statistics

6

11

4

0

2

4

6

8

10

12

15-16 16-17 17-18

Implemented Projects

Savings in Rs. Million p.a


Energy Saving Projects Implemented in

FY 2015-16

S

No

Title of Energy Saving project

implemented

Annual Electrical

Savings achieved

Annual thermal

savings

Total

Annual

Savings

Invest.

Made Payback

months Units

Million

Rs

Million

Tons of

Fuel

Rs

Million

Rs

Million

Rs

Million

1 Increasing the area of 10-E-57

(Regeneration gas feed/effluent) in Cracker --- --- 289 12.39 12.39 4.07

4

2

Stopping one cooling water pump in CT-1

tower by replacing all 6 CW pumps with

new high efficiency CW pumps in O&U

2.63 13.2 --- --- 13.2 10.2 9

3

Providing PRDS water injection by running

BFW pump & stopping one PRDS water

injection pump in CPP

0.18 1.518 --- --- 1.52 1 8

4

Direct supply of makeup water to CT1 and

CT2, hence one water makeup pump

stoppage in O&U

0.35 2.74 --- --- 2.74 1.5 7

5

Replacement of 125 W HPMV lamps with

50 W LED Lighting Fixture in PP bagging

Warehouse area (95% completed)

0.25 0.9 --- --- 0.9 1.5 20

6 Provide additional spare heat exchanger in

parallel to 10-E41D in cracker --- --- 152 6.41 6.41 4.5 9

Sub Total 3.41 18.36 441.81 18.80 37.16 22.77


Energy Saving Projects Implemented

in FY 2016-17

S

no

Title of Energy Saving project

implemented

Annual

Electrical

Savings

achieved

Annual

thermal

savings

Total

Annual

Savings

Invest.

Made Payback

months

Units

Million

Rs

Million

Tons

of

Fuel

Rs

Million

Rs

Million

Rs

Million

1 GT3 uprate --- --- 2546 62.00 61.67 67.60 14

2 Use of available chilling capacity from

LDPE VAR to LLD AHUs 0.700 2.790 --- --- 2.79 4.60

20

3 150W HPSV street lights by 90W LED

lights 0.001 0.003 --- --- 0.001 0.003 36.0

4 Provision of HP residue gas line to HP

knock out drum for GTG fuel --- --- 5689 138.00 137.79 0.90 1

5 VAR machine temperature control in

EOEG --- --- 48 1.00 1.16 Nil --


Energy Saving Projects Implemented in

FY 2016-17

S No Title of Energy Saving project

implemented

Annual

Electrical

Savings

achieved

Annual thermal

savings

Total

Annual

Savings

Invest.

Made Payback

months

Units

Million

Rs

Million

Tons

of Fuel

Rs

Million

Rs

Million

Rs

Million

6 Reduction in steam consumption

by derating HP steam control valve --- --- 300 7.0 7.3 0.10 1

7 Stoppage of VAR in DHC and use of

AC in laboratory --- --- 103 3.0 2.5 0.10 1

8 Increasing steam insulation

thickness based on fuel prices --- --- 80 2.0 1.93 4.0

25

9 Demo furnace convection section

dry Ice blasting --- --- 52 1.3 1.27 0.395

4

10 EOEG - BFW - END OF CYCLE - One

pump operation 0.82 2 --- --- 2 --- ---

11 Stoppage of nitrogen compressor

in ASP 3.25 4.6 --- --- 4.6 --- ---

Sub Total 4.77 9.4 8818.5 214.3 216.4 77.7


Energy Saving Projects Implemented

in FY 2017-18

S No Title of Energy Saving project

implemented

Annual

Electrical

Savings

achieved

Annual thermal

savings

Total

Annual

Savings

Invest.

Made Paybac

k

months Units

Million

Rs

Million

Tons of

Fuel

Rs

Million

Rs

Million

Rs

Million

1 LP Condensate heat recovery in

Cracker --- --- 534.4 3.7 3.7 3.00 10

2

GC furnaces Convection bank

cleaning and refractory

replacement

--- --- 4441.3 80.6 80.6 50 8

3

CG compressor turbine

efficiency improvement

--- --- 5737.8 103.3 103.3 80 10

4 C2R compressor turbine

efficiency improvement --- --- 201.5 3.6 3.6 3 10

Sub Total 10914.9 191.2 191.2 136


CG Compressor Turbine Efficiency

improvement • Cracked Gas Compressor Train is most critical and energy intensive machine of Gas

Cracker plant. Efficiency of this machine is critical for site energy consumption.

• CG Turbine is MHI make Condensing-Extraction type turbine installed in year 1989.

• Historically the turbine was operating at lower efficiencies than Design Efficiency

for HP & LP section.


CG Compressor Turbine Efficiency

improvement


CG Turbine Efficiency Improvement

CG Turbine: Before Revamp After Revamp

Shaft Power 19.93 MW 23.0 MW

Speed (max.) 5,794 rpm 5,580 rpm

Steam Flow 108 T/H 125 T/H

50

60

70

80

90

HP Side

Efficiency

LP Side

Efficiency

Pre Revamp 67.76 80.4

Post Revamp 72.1 89.4

67.76

80.4

72.1

89.4

CG Turbine Efficiency (%)

Pre Revamp Post Revamp

• Investment of Rs. 8 Cr. for modification

• Returns:

Energy Saving-6.5 Gcal/Hr.

Rs. 10.33 Cr. Annual savings

CG & C2R Compressor Turbine Efficiency

58

60

62

64

66

68

Efficiency

Before 62

Post Revamp 67

62

67

C2R Turbine efficiency (%)

Before Post Revamp


CG & C2R Compressor Turbine Efficiency


Innovative Project

Skin

temperature

reduced from

5000C to 1800C Convection tubes of

5th (Dil steam +HC: 24

tubes) & 6th (Dil

steam: 6 tubes) banks

were pulled out (total

30 no. tubes) from all

5 furnaces, inspected,

cleaned and installed.

Fuel

consumption

reduced by

35Kg/hr in each

furnace

Savings: 4441

Tons of fuel p a

Gas cracker furnaces convection banks were choked but couldn’t be cleaned due to no access.

.

Challenges faced After removal of tubes, it was

observed that the insulation inside has

corbel joints at two locations. This was

not envisaged during ordering of the

insulation material. Hence Pyro bloc

insulation modules were made and

installed to form Corbel joints to suit

the site.


Solar panel installation of 15 MW potential identified.

Phase 1: 0.75 MW solar panel installation on water tanks is under approval

Proposed site

Typical Installation

• Site study and feasibility completed

• Site visit of EPC agency completed

• Budgetary Techno-commercial proposal

received from EPC agency.

• Financial working completed.

Renewable Energy


Solar lamp distribution in near by villages: 34 Solar lamps of capacity to run for 4 hrs, which saves 2.8 MWH per annum conventional energy.

Solar water heaters installed in Umang Hostel

Purchasing of Renewable energy is under exploration

Rain water harvesting is being done every year @ 500 m3/day.

Renewable Energy


S No Type of Waste Fuel used

Quantity of

waste fuel

used (Tons)

Equivalent of

Conventional energy

used (Gcal)

1 C9+ from Cracker is used in RPET burners

(earlier sent to landfill site) 270 81

2 HP residue gas to CPP

(earlier sent to flare) 10800 12866

Utilisation of Waste Material as Fuel

C9+ mixture: Generated in Cracker containing some solid particles, hence this mixture

cannot be used in main boilers considering reliable steam requirement of process plants.

It was being sent to incinerator or landfill. Later evaluated to utilize in RPET furnace for

thermic fluid heating.

Residue gas: Generated in Cracker containing mixture of Methane and Hydrogen. Normally

used in furnaces and boilers, but during high amount of Propane cracking this generation

quantity increases, hence some quantity is forced to flare. Later scheme prepared to utilize

this gas in Gas turbines for power generation.

Quantity saved in last 3 years:


GHG Emission Reduction

Scope 1 Emissions: Fuel combustion, Flaring

Scope 2 Emissions: Import of electricity

Excluding

shutdown

flaring


Green Supply Chain

Capacity enhancement of trucks for material transport

• Considering base line of 2011-12 truck capacity was around 10-10.5 MT

• Current truck capacity is around 17 MT indicating an increase of 70%

in truck load

• We further target to increase truck load by 5% annually.

Increase in CO2 transport to customer

• In year 2015, NMD started selling CO2 for productive use instead of venting.

• CO2 supply to customer in 2015-16 was 1931 MT which increased to 11960 MT in 2017-18

indicating rise of over 500%. Further increase of 10% is planned for it on annual basis.


Green Supply Chain

RORO Facility for Product Transportation to

Mangalore

Transportation of the products to Mangalore

through train to avoid road transportation resulted

ìn CO2 emissions reduction

Empty bag weight reduction

Reduction of 10 gm weight of each empty bag

resulted in reduction of polymer material by

approx. 200 MT/year

130 126 120

115 110

100

120

140

Empty Bag Weight in gm

2000 2004 2010 2012 2017


Green Supply Chain

Elimination Inter Plant movement for product loading • Truck weighing 16-35 MT was moving from one plant to another plant consuming diesel.

By eliminating inter plant movements, diesel consumption was saved.

Before

Truck reports at one

plant

Product Bags loaded

Temp tarpaulin tying

Truck reports to second

plant

Product Bags loaded

Tarpaulin tying

Now

Truck reports at one plant

Product Bags loaded

Product bags from other

plants

brought by forklifts

Tarpaulin tying

CO2 reduction of

317 Tons

(2017-18)


Review of Energy Performance

Oversee site Energy Performance

Networking with corporate, vendors and

academics to identify improvement areas

Measurement and Monitoring

Implementing improvements

Energy Audits

Spreading Awareness

Top to bottom, bottom to top approach

Corporate Energy Cell

Site Apex

Site Energy

Cell

Small group

Working Level

Review Energy Cons. trend

Review status of schemes

Providing resources and drive

Ideating (KAIZEN) & Mission Kurukshetra

Participation in improvement projects

Evaluate & prioritize Energy schemes

Benchmarking

Guidelines to working group

Support for Decision making

Energy & Fuel Management

Weekly energy variance review with all sites

Measurement and Monitoring

Implementing improvements

Energy Audits

Spreading Awareness

Apex : (Monthly, chaired by P-NMD)

Core : (Corporate Energy Cell)

Working Team : (Site-Energy Coordinators)

Small Group : (Site)

Energy Cell : (Site)


Energy Monitoring

Whatever gets measured gets done

Real time monitoring of Steam & Fuel

Prosteam Optimizer

Daily Monitoring &

Reporting

Energy Review with Site Apex

Energy Professionals Networking

SMART Manufacturing_

Energy dashboard

Optimizer is used for

overall steam and fuel

balance of the site.

Real time data is taken

on hourly basis and the

software recommends

the optimized way of

running the plant

- Daily monitoring

and reporting of

the steam and

fuel balance of

the site through

Daily Energy

Report

- Plant wise daily

reporting of the

energy

consumptions

Dashboards for monitoring the hourly

average data of the plant and site

parameters (including energy)

Monthly Intersite

networking of the Energy

group done for reviewing

site Energy performance

by CoE, for new

technology updates,

EnCon ideas, suggestion

and constraints.


Monthly steam trap monitoring

Replacing all Thermodynamic traps with Bimetallic/Inverted bucket traps

Feb’18 July’18

Steam Trap Monitoring


Norms

• Energy & Utility Norms setting is an annual exercise.

• Unit performance is assessed in detail on monthly basis with agreed norms

Intent

• Optimize the consumption of Energy & Utilities of the complex

• Establish the baseline norms for assessing plant performance throughout the year

Principle

• Setting SMART goals

• Setting stretch goals based upon benchmarks & best achieved figures considering technology and type

Standard

• Corporate standard available for setting norms for the financial year

Average of two lowest process entitlements in last three years

Adjustments done to take care of any abnormalities in technology, equipment performance, plant load, etc.,

Efficiencies of major energy intensive equipment consideration

Improvement measures under implementation & planned in financial year

CoE review & Site CTS chief approval

Benchmarking with intra-site & internationally by CoE

Quarterly review of actual norms against the target

EnCon Target Setting and Monitoring


Capability Building Training Programs

Training Need Identification (TNI) is done at the start of the year

Other than TNI, training/awareness programs are conducted as below:


EnCon Week

EnCon quiz

EnCon token gift

distribution

EnCon Suggestion

EnCon Crossword in School

EnCon awareness sessions in township

Involvement of all stake holders

EnCon Programs


Involvement of School

Children

Energy awarene

ss Posters

Energy awareness Program

Mission Kurukshetra Portal

Energy Saving tips

through mail

Involvement of Family members

Involvement of

community members

Energy training

Participation in External trainings

Engagement of all stakeholders

Awareness & Involvement


Implementation of ISO 50001:2011

ISO 50001:2011:

Energy Management

system implemented in

year 2014 and

recertified in year 2017


GreenCo Rating

NMD Site rated as a GreenCo Gold u it as pe fulfill e t of the e ui e e ts in accordance with Gold level of GreenCo Rating System in year 2017

Attained the distinction of being the 1st Petro Chemical Complex to be rated

ith the p estigious GreenCo Rati g i the country


Site Awards & Accolades

• Won Ce tifi ate of E elle e i 12th State Level Awards for Excellence i E e g Co se atio a d Ma age e t fo 6-17.

• Won GreenCo Gold Rating-CII in Petrochemical Sector – 2017.

• Won Natio al a a d fo E elle t E e g Effi ie t U it CII fo ea 14-15 for consecutive 3rd time.

• Won BEE National Energy Conservation Award –First prize in Petrochemical sector for the year 13-14.

• MEDA State Award for Best Energy Efficient Unit – First prize for 2013, 2014 and 2015

Energy

• Golden Peacock National Quality Award - 2012 & 2015

• RBNQA 2012 – Commendation Certificate

• RBNQA 2016 – Performance Excellence

Quality


Site Awards & Accolades

•APEX India Afforestation Excellence Award 2017 under Platinum category

•Golden Peacock Occupational Health & Safety Award - 2013 & 2015

•Green tech Safety Award - 2013

•ICC award for Management in Health, Safety & Environment for the year 2012

•National Safety Award - Ministry of Labor, Government of India for Meritorious

Performance

•Five star accreditation from British safety Council – 2003 & 2008

•Award for Meritorious Performance from Council of Industrial Safety

•Certificate of Merit from FPA-UK for High Standards in the Mgt. of Fire Systems &

procedures

•Longest Accident Free Period from NSC – Maharashtra Chapter

• Maha asht a State Vanshree A a d - First rank

• Best Environmental & Ecological Implementation, from International Greenland

Society

• Indo-German Green-Tech Environment Excellence Award 2000-2001 & 2002-2003

Safety & Environment


ENCON Road Map

Aggressive plan to reduce 5% Energy consumption by 2020-21.

High Energy prices, aggressive ENCON schemes


ENCON Road Map

Plan 2018-19:

1. Steam trap replacement in GC/EOEG/CPP/O&U/LDPE/PP.

2. Engineering of SVH-SM back pressure turbine generator.

3. Engineering of GT inlet air path modification.

Plan 2019-20:

1. Installation of SVH to SM Back pressure Turbine with Synchronous Generator at CPP.

2. GT inlet air path modification to reduce pressure drop.

3. Installation of Solar panels for 0.75 MW power generation.

4. Restoration of 10-P-41A QW pump turbine to minimize steam letdown.

5. Cooling Tower-2 cooling water system augmentation.

6. Installation of new Air compressor to reduce operating costs.

Sayantan Bhowmik Head Technology Rotary Cell Energy Manager

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