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Grasim Industries Limited – Chemical Division Unit – Rehla
Welcomes You
Unit History
• In 1984, Incorporated as a joint venture of the Aditya Birla Group 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 India Limited.
• Jan 2016, Merged into Grasim Industries 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 Renukoot 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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