presentation at msu case studies in chemical industries
TRANSCRIPT
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ENERGY CONSERVATION IN CHEMICAL INDUSTRIES
CASE STUDIES
05/02/2023 05:13 PM GSFC ltd. 1J P PATEL
By
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ENERGY CONSERVATION
• The quickest, cheapest and the most practical
method of energy savings.• Energy is a manageable expense, and it can be
easily controlled through dedicated efforts.• “communication, culture and commitment are
the key driving forces for us in making ‘conservation of energy a way of life’ at our works.
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• The latest is LED lighting . A 15 watt CFL can be replaced by 7 watt LED . And the carbon emission level is 8 gm /hr.
Ref- BEE EA text book
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ENERGY MANAGEMENT STRATEGIES
1. Energy Conservation If you don’t need it turn it off.
2. Energy Efficiency If you need it do it more efficiently
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ENERGY TRANSFORMATION
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About GSFC…...• GSFC is an integrated complex for
manufacturing of Fertilizers, Petrochemicals, Polymers, Fibers etc.
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• GSFC also have in built Co-Generation system to make complex, self sufficient for the need of power and steam.
• GSFC has installed capacity of 124 MW of wind mill.
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THE MAIN REASONS FOR HIGHER SPECIFIC CONSUMPTIONS IN INDIAN INDUSTRIES
Obsolete technology.Lower capacity utilization.Casual metering and monitoring of energy
consumption.Lower automation.Poor raw material quality.Poor handling, operating and maintenance
practices.05/02/2023 05:13 PM GSFC ltd. 7
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AREAS IN WHICH ENERGY CONSERVATION IS POSSIBLE
• Power Pumps, compressors, fans, blowers
• Steam Steam production & distribution network
• Natural gas Furnaces
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COST OF ENERGY
• Power =Rs. 7.5 / kWh =• Steam =Rs. 2720 / MT=• Natural =Rs. 34 / SM3 = Gas
NCV of Natural gas = 8400- 8700 Kcal/sm3
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8.7 Rs/1000Kcal 4.18 Rs/1000Kcal 4 Rs/1000Kcal
Enthalpy of steam = 650 Kcal/kg
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Energy Management Cell, WBSEB
SECTOR WISE ENERGY CONSUMPTION
Type of Consumer Percentage of Consumption
Agricultural 5
Industry 49
Transport 22
Residential 10
Others 14
Agricultural
Industry
Transport
Residential
Others
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ENERGY SAVING OPPORTUNITIES IN STEAMDesuperheating of steam
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P = 37 Kg/cm2.gT = 350 0CM = 40 MT/Hr
PCV
P = 20 KT = 320 0C
Desuperheater
BFW
P = 20 Kg/cm2.gT = 250 0CM= 43.4 MT/Hr
Super heated steam acts as an inert gas and hence reduces heat transfer coefficient.
Desuperheating resulted into more steam generation by ~3.5 MT/Hr.
It can result into capacity limitation at higher load.
STH
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THERMO-COMPRESSOR SYSTEM
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LPS
HPS
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THERMO COMPRESSOR TECHNOLOGY
• Useful when low pressure steam is being vented / condensed.
• Requirement of medium pressure steam is met by throttling high pressure steam.
• Higher pressure of MPS requires high amount of HPS.
• Quantity of MPS determines recovery rate of LPS.• Very attractive pay back period.• Becoming popular.
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POWER SAVING IN COMPRESSORS• Provision of Inter stage coolers.• Adequate CW supply to inter stage coolers.• Clean heat transfer surface of Inter stage
coolers.• Low inlet temperature of feed gas.• Low temperature of cooling water.• Less handling of inlet mass.• Reduce the discharge pressure of
compressor if process permits
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power saving done in centrifugal compressor by reducing discharge pressure from 11.5 kg.cm2 to 11 kg.cm2 .g
Power saving=1.73*11*4*0.9=68.5 kw68kwh*7.5 Rs/unit= Rs 513 per hr
• BEFOREAMP Drawn=54
• AFTERAMP Drawn=50
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CASE STUDY- 1POWER SAVING IN COMPRESSORS
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CASE STUDY-2POWER SAVING IN COMPRESSORS
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CASE STUDY-2POWER SAVING IN NH3 COMPRESSORS
• LESS HANDLING OF INLET MASS• 24% NH3 solution preparation scheme:• Liquid ammonia is supplied as refrigerant. Vapour
ammonia generated due to absorption of process heat was supplied to Reciprocating vapour ammonia compressors.
• Part of vapour ammonia absorbed in DMW to prepare 24% NH3 solution, which is required raw material in Capro-Lactam plant.
• Resulted into less power consumption by compressors due to reduction in loading step for Reciprocating vapour ammonia compressors.
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CASE STUDY-3 : WASTE HEAT UTILIZATION
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E-405-5
CW
D-405-3
LBP column-II T-406-2
HE
T=135 0C
T=95 0C
T=50 0C
T=50 0C
T=85 0C
H2
Dehydrogenation product
Steam saving = 140 Kg/Hr (1120 MTPY)(Rs. 16.8 lacs/Yr), Cost of modification = ~Rs. 5 lacs Payback period = 0.3 years
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ENERGY EFFICIENCY IN PUMPS
4. Trimming of impeller.
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1. Optimization of pumping system.
Following are the ways to improve performance and there by to reduce power consumption.
3. Improving network system to reduce pumping requirement.
5. Replacement of old and inefficient pump with new and higher efficiency pump.
2. Installation of optimum size pump/motor
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CASE STUDY-1-Trimming of impeller
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Liq NH3 to consumers P=~17 barg
P-601-A
Vap NH3 to Ref. comp.
MP Flash drum
LP Flash drum
NH3 storage tank
L= ~2 Kms
VO = 5 %
Flow m3/Hr Pressure bargPower kWhImp.dia. mm
Design820735325
Before1810.327325
Recent186.720264
56 m3/Hr
P= 0.5 barg
Power saving = 0.56 lacs units /yr (Rs. 4.2 lacs /yr
VO = 10 %
Liq. NH3
LCV
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CASE STUDY-2- Trimming of impellerCase of proper capacity utilization
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FV-402-01
E-402-1 E-402-2 E-402-4To T-402-1 (8.80
kg/cm2)
press= kg/cm2
P-404-1A/1B
FT-402-01
SKETCH FOR SUGGETION OF P-404-1A/1B
17.5
17 10
D-404-1
3.8
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CASE STUDY-2-Trimming of impeller
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Impeller of the above pump trimmed & motor of the pump replaced by 75 kw, earlier it was of 90 kw
Before AfterMotor, kw 90 75
Impeller diameter,mm 355 340
AMP 100 90power drawn(kwh) 64.6 58.2
Rs/kwh 7.5 7.5
RS 484.6 436.2
SAVING RS/Hr 48.5
SAVING RS/Yr 387693
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Pump follows following equations after Trimming of impeller(Affinity laws)
• Q2/Q1 = D2/D1
• H2/H1 = (D2/D1)^2
• P2/P1 = (D2/D1)^3
Where, Q = Flow in m3/Hr, H = Head in meters and HP = power in kWh, D= impeller diameter
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CASE STUDY-3 Installation of higher efficiency pump
/ Improvement in efficiency
CW circulation pump (P-012-1A/B/C), Caprolactam-I Plant:
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• CW pumps were running since commissioning of plant in 1974. Based on survey carried out, pumps were found running at very low efficiency -55 %
• New set of pumps installed having higher head, capacity and better efficiency.
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INSTALLATION OF HIGHER EFFICIENCY PUMPS..(CONT)
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6 meter elevation
12 meter elevation
18 meter elevation
24 meter elevation
From CT basin
It is possible to meet plant requirement at 110 % load.
Pump ή = 55%Pump ή = 80%
BEFOREM= 5800 m3/HrH = 35 meterP = 980 kWhή = 55 %AFTERM= 6800 m3/HrH = 40 meterP = 990 kWhή = 80 %
Power cons/m3 circulation Before = 0.169 After = 0.146
Booster pumps
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WHAT IS OUR ROLE?
Energy conservation becomes our joint responsibility, be it the industries, individual citizens, organizations, oil companies, or the government.
Each one of us has a specific and significant role to play.
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CONCLUSION
∑(Little Ideas)= Big Result
∑(Wisdom + Effort) = Reduction of Energy
Cost Without Investment
Many Drops Make a SHOWER
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