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Grasim Industries Limited – Chemical Division Unit – Rehla

Welcomes You

Unit History

• In 1984, Incorporated as a joint venture of the and the Bihar State Industrial Development Corporation.

• In 2003, Management control taken over by Aditya Birla Group, Hindalco Industries.

• On 14th Jan 2009, became fully owned Aditya Birla Group unit as Aditya Birla Chemical Limited.

• Jan 2016, Merged into limited as Chemical Division.

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Unit Location

City Distance by Road (KM) Ranchi 203 Varanasi 230 Patna 254 Kolkata 632

Unit History – Technology

Sept 1984 : 110 TPD , Mercury Cell Technology

Sept 2000 : 30 MW Thermal Power Plant, ThyssenKrupp with BHEL Turbine.

Nov 2005 : Mercury Cell Technology Abandoned.

Feb 2006 : 225 TPD, Membrane Cell, TKIS (UDHE)

Mar 2008 : Stable Bleaching Powder, 48 TPD, Nuberg Engineers.

May 2006 : Aluminium Chloride, 25 TPD, Lele Consultant.

Jan 2009 : 300 TPD, Membrane Cell, TKIS (UDHE).

May 2011 : Aluminium Chloride capacity Enhancement, to 45 TPD.

Mar 2014 : 30 MW Thermal Power Plant, ISGEC with BHEL Turbine.

Dec 2015 : First 6th Generation Electrolyser installed in INDIA. Dec 2016 : 100 TPD Flaking Plant, M/s Bertrams Current Production : 300 TPD, with 60 MW Power availability.

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Unit History – Technology

Products Unit 1984 02-03 05 -06 08-09 14-15 16-17 18-19

Caustic Soda (NaOH) (TPD) 300 300 300 100 160 225 300

Liquid Chlorine (Cl2) (TPD) 250 250 250 40 90 160 250

Hydrochloric Acid (HCl) (TPD) 125 125 125 50 60 125 125

Sodium Hypochlorite (NaOCl) (TPD) 4 4 4 - 1 4 4

Compressed Hydrogen Gas Lac NM3 / month - - 1.5 1.5 3.0 3.0 3.0

Aluminium Chloride Anhydrous TPD

- - - 32 32 39 45

Stable Bleaching Powder (SBP)

TPD - - - 48 48 62 62

Caustic Soda Flakes TPD - - - - - 100 100

Unit History – Technology

Caustic Production Vs Total MTOE/Yr 110000 117000.00

108000 116000.00

106000 115000.00

104000 114000.00

102000 113000.00

100000 112000.00

98000 111000.00

96000 110000.00

94000 109000.00

92000 108000.00 16-17 17-18 18-19

Caustic Soda (in MT) TOTAL MTOE /Year Energy Source includes • Coal – Captive Power Plant, 2x30 MW CFBC Boiler. • Hydrogen – Co Product. • Grid net Balance – Difference between Export & Import.

• ** Considering GCV of Oil 10,000

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FY 18-19: Source Energy Consumption

4058; 3%

8890; 7%

120381; 90%

Thermal Electrical Hydrogen

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FY 18-19 : Energy Consumption 14000 10000

12000 9500

10000 9000

8000 8500 6000

8000 4000

7500 2000

0 7000 Apr'18 May'18 Jun'18 July'18 Aug'18 SEP'18 Oct'18 Nov'18 Dec'18 Jan'19 Feb'19 Mar'19

Thermal Electrical Hydrogen Caustic Soda (in MT)

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Power Consumers

Cell Power : Is defined as the total power utilized directly in process of electrolysis.

Factors Effecting Cell Power • Aging of Membrane – 15 kWh/ton of Caustic, Re Membraning in a duration of 4Years • Coating Depletion for Anode and Cathode Pans, Recoating in a duration of 8 Years. • Higher Current Density Operations. • Generation of Electrolysers • Gen IV – 2180 kWh/ton @ 4.75 CD • Gen V – 2030 kWH/ton @ 4.75 CD • Gen VI – 2005kWh/ton @ 5.00 CD

Aux Power : Is defined as the additional power required for associated equipments. Factors Effecting Aux Power • Hcl and Liquid Chlorine production percentage. • Power associated with utility, Cooling Water and Chilled Water. • Media for Liq. Chlorine pumping.

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Synergy and Bench Marking – AC Cell Power

FY17 FY18 FY 19 Units Target Actual Target Actual Target Actual

Nagda-I 2125 2143 2130 2116 2129 2120

Rehela 2262 2256 2264 2195 2172 2176

RNQ-Ph-II 2184 2161 2245 2151 2224 2205

Vilayat 2155 2121 2162 2152 2113 2095

Karwar 2069 2052 2088 2069 2206 2150

Ganjam 2158 2299 2202 2100 2131 2113

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Initiatives taken for Cell Power reduction

FY 16 -17 Electrolyser “A” Conversation from IV to VI Generation- Investment 13.00 Cr.

FY 17-18 Electrolyser C Reacoating, Generation IV - Investment 3.82 Cr.

FY 18-19 Electrolyser “B” Conversation from IV to VI Generation - Investment 13.74 Cr Electrolyser E Reacoating, Generation V - Investment 4.14 Cr.

In Progress Electrolyser “D” Conversation from IV to VI Generation - Investment 15.00 Cr.

Accumulated Savings FY 16-17 : 0.69 Cr. FY 17-18 : 3.70 Cr. Fy 18-19 : 6.53 Cr.

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Cell Power Performance FY 18-19

Generation Conversion in Dec 18, and recoating in Feb 19. 2220 350 2200 2201 2203 2194 2197 2200 2192 2190 2193 300

2180 250

2160 2149 2141 200 2140 2132 2120 150 2120

100 2100

2080 50

2060 0 Apr-18 May-18 Jun-18 Jul-18 Aug-18 Sep-18 Oct-18 Nov-18 Dec-18 Jan-19 Feb-19 Mar-19

Cell Power Production

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Synergy and Bench Marking – Aux Power

FY17 FY18 FY 19 Units Target Actual Target Actual Target Actual Nagda-I 158 176 158 173 173 180 Nagda-II 162 188 175 177 180 187 Veraval ** 162 168 161 158 160 163 Rehela 180 208 189 191 190 179 160 169 165 172 165 165 Vilayat 160 177 166 166 187 195 Karwar ** 148 152 151 150 152 135 Ganjam 200 228 200 216 195 211

** - High HCl producing Units not being compared

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Auxiliary Power Reduction in FY 18-19

Action Taken • Cooling and Chilled Water. • Stoppage of Rectifier Hot well pump 1.45 KWH/Ton. • Energy Efficient Pumps at Main Cooling Water 26.5 to 21.0 KWH/Ton. • Energy Efficient Pump at Chilled Water Circulation. 6.86 to 4.27 KWH/Ton.

• Chlorine Compression and Liquefaction, with load rise of 25 Tons. • Operating compressor at higher suction pressure. 41 to 42 KWH/Ton • Available residual capacity of liquefier and load balance 44 to 38 KWH./Ton

Still Working on • Compressed air system. • Further reduction in cooling water – for Caustic Concentration Unit.

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Auxiliary Power Performance FY 18-19

Aux Power in kWh/ton 195 350

190 300

185 250

180 200

175

150 170

100 165

50 160

155 0 Apr-18 May-18 Jun-18 Jul-18 Aug-18 Sep-18 Oct-18 Nov-18 Dec-18 Jan-19 Feb-19 Mar-19

Aux Power Production

Reduction Auxiliary Power – Power Plant

Concern • Higher Auxiliary power consumption at lower Plant Load factor. • Design 11.5 % @ 100 % PLF Achieved 14.5 % @ 78 % PLF Actin Taken • De-staging of boiler feed water pump impeller • Impeller Replacement at • ID Fan • Cooling Water Pumps • VFD Installation at • Secondary air fans • Condensate extraction pumps • Replacement (also resized) Energy efficient pump at Aux. cooling water. Results • Total Saving – 452 KW (1.02 % @ 78 % PLF) Unit 2 : 364 KW Unit 1 : 88 KW Way Ahead • VFD Installation at PA Fans & Boiler feed water pump. • Impeller Replacement at ID fan at Unit-1

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Reduction Auxiliary Power

Target for Energy Effeciency

1. Installation of VFD in CPP#1 PA Fan motor B & C 400 Kw 3.3 Kv a. It is proposed to install medium voltage 3.3 Kv variable frequency drive in 400 Kw 3.3 Kv motor of P.A. Fan Motor B & C of CPP unit#1. This will give an estimated saving of approx. 94 Kw/hr i.e. 2256 Kwh/day.

2. Installation of VFD in CPP#2 PA Fan motor A & B 400 Kw 3.3 Kv a. It is proposed to install medium voltage 3.3 Kv variable frequency drive in 400 Kw 3.3 Kv motor of P.A. Fan Motor B & C of CPP unit#1. This will give an estimated saving of approx. 104 Kw/hr i.e. 2496 Kwh/day.

3. Extra One cell addition to Cooling Tower of Unit-2 a. Cooling Tower of Unit-2 is not performing well as per performance study conducted by OEM M/s Paltec and M/s Encon where L/G ratio is high and affect Cooling Tower performance which resulted condenser performance. Also Riser Pipe valve is opened only 70% which return back from condenser cooling water outlet because at 100% valve opening, water overflow from hot basin. Throttle valve opening resulted back pressure on pump and high energy consumption. 18

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Target for Energy Effeciency

4. Conversion from 4th Gen to 6th Gen

Conversion of Electrolyser D from 4th Gen to 6th Gen which will save

30 KWH /Ton of Caustic

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CO2 Emission

Year Total Kg CO2/Ton of Final Product 2016-2017 3458 2017-2018 3621 2018-2019 3086.6

CO2 Intensity- FY 19-20 1. CO2 generation of per ton of product 2903 Kg 2. CO2 generation of per MW 1.100299627

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Awards & Achievements

1. Energy Conservation Award - PAT - 1 cycle by Bureau of Energy Efficiency, New Delhi

2. National Energy Conservation Award 2018 Won Second Prize in the Chlor-Alkali Sector.

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Thanks ?

Vivek Mishra Mail to :[email protected] Mob:9174002811

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