Asian Paints Limited Penta Division Cuddalore

EXCELLENCE IN ENERGY MANAGEMENT

BY

ASIAN PAINTS LTD.PENTA DIVISION, CUDDALORE.

ABOUT US …

Asian Paints is India’s largest Paint Company and ranked amongthe Top 10 decorative coating companies in the World.

We have 28 Manufacturing facilities across the World servicingConsumers in 65 Countries.

In India, we have 9 plants manufacturing coatings and 2 plantsmanufacturing chemicals. Our Unit manufacturing Pentaerythritol is located at Cuddalore, Tamilnadu.

Penta Division is accredited with ISO 14001 and OHSAS 18001certification and manufacturers following chemicals :

Various grades of PentaerythritolSodium FormateFormaldehyde

We have an enviable reputation for innovative Energy conservationpractices which helped us to bring down the specific energyconsumption, helping the division survive.

PROCESS

Involves precisely controlled Reaction of Formaldehyde and Acetaldehyde in the presence of Caustic soda.

The product of the Reactor is concentrated by Evaporation followed by Crystallization and separation in a Vacuum belt filter.

The product of Vacuum belt filter is purified, dried and sent for packing.

Reaction

Crystalliser

Pure Vacuum Crystallizer

Tech Dissolver

TO AIR

PE : Pentaerythritol

Ca

FaAa

Distillation Column

For Formaldehyde and Methanol Recovery

Sodium Formate Drier

Sodium Formate Bagging

TO AIR

Crystalliser Mech Sieving

PROCESS BLOCK DIAGRAM

Knock Down Tank

Stripper Five Effect Evaporator

Crude Vacuum Crystalliser

Crude Belt Filter

Deionizer / Carbon columns

Tech PE Drier

TO AIR

Tech PE Bagging

Tech PE Silo

Mono PE Drier

TO AIR

Mono PE Bagging

Mono PE Silo

Di PE Bagging

Crude Mother Liquor

Di PE Drier

Di PESilo

ENERGY COSTING

The Co-Gen system generatesrequired Electrical energy.Cost of imported Energy fromthe grid alone is captured asElectrical energy cost.

75.6

24.4

94.1

5.9

95.2

4.8

0

20

40

60

80

100

2009-10 2010-11 2011-12

Electrical Energy CostThermal Energy Cost

Energy Cost accounts for 19% of the total manufacturing cost and 48% of the plant overheads in FY 2011-12.

Working towards achieving zero

grid power consumption

Sl.No.

Activity (2009-10) Investment (RL)

Reduction in specific steam

consumption in MT/TPE

Reduction in specific power

consumption in kwhr /TPE

Power savings

per annum (Units in

Lacs)

Fuel (COAL of 6000 kcal) Saving per

annum (MT)

Cost Saving Per annum

(RL) Saving as % of energy bill

1. Replacing Crude Belt Filter (CBF) Vacuum pump with Energy efficient pump

1.1 --- 15.4 0.73 --- 3.27

0.41 %

2. Replacing Pure Belt Filter (PBF) Vacuum pump with Energy efficient pump

0.96 --- 13.7 0.65 --- 2.9

0.37 %

3. Replacing the low pressure Boiler of 20.5 KSC Pressure, 14 TPH capacity and low Efficiency Turbine with high pressure Boiler of 45 KSC Pressure and High Efficiency Turbine to increase the power generation from the Back pressure Turbo Alternator for the same Steam flow.

749 --- --- 36.29 --- 163.3

20.6 %

4. Reducing 1500 KVA Turbo Alternator frequency from 50 Hz to 48.5 Hz

0 --- 108.4 5.09 --- 22.93

2.9 %

Contd . . .

ENERGY CONSERVATION ACTIVITIES 2009 to 2012

S.No Activity (2009-10) Investment (RL)





Power savings

per annum (Units in

Lacs)


annum (MT)



5. Increasing the production/Rxn. by Increasing the Initial Formaldehyde concentration from 10.1 to 10.5 leading to reduction in energy consumption (Reduction in water input into the process)

0 --- 10.29 0.48 --- 2.18

2.7 %

6. Replacement of Pressure Reducing Station (PRV for 45 to 5.2 KSC) with Thermo compressor for increasing power generation through turbine. (Even though this activity has resulted in an additional power generation of 168 KW which is around 15% of our total power consumption, the same will not get reflected in Specific energy consumption)

7.0 --- --- 13.55 --- 60.96

7.67 %

7. Firing of Waste gas containing Hydrogen and traces of methanol from Formaldehyde plant in boiler for generating steam

1.6 --- --- --- 961 45.17

5.69 %

8. Installation of 2Nos of 18.5 KW VFD for Cooling Tower Fan application.

1.6 --- 15.44 0.73 --- 3.99

0.5 %Contd . . .

Sl.No

Activity (2010-11) Invest-ment (RL)





Power savings

per annum (Units in

Lacs)


annum (MT)



9. Reducing Cooling Water circulation flow rate by replacing 3 Nos. of Shell and Tube Heat Exchangers with a single PHE in distillate line going to Reactor.

3.75 0.037 19.4 1.05 32.63 6.29

0.68 %

10. Optimization of Batch cycle time in Vacuum Crystallizer by Removing the Cyclone separator which was a part of imported crystallizer.

0 0.202 --- --- 176.8 8.48

0.92 %

11. Increasing the Power throughput across the Turbo Alternator (Back pressure Turbine) by increasing the steam drawn through the Turbine and simultaneously reducing the HP steam consumption which is bypassing the turbine. The medium pressure requirement is reduced from 5.2 to 4.8 KSC by increasing the Heat transfer area of the Re-boiler. However the overall steam consumption remains the same. (Even though this activity has resulted in an additional Power Generation of 41.25 KW, the same will not get reflected in Specific Power consumption. Indirectly the power drawn from the TNEB grid has reduced to that extent.)

4.62 --- --- 3.33 5.8 14.97

1.63 %

Contd . . .

Sl.No






Power savings

per annum (Units in

Lacs)


annum (MT)



12. Replacing 150 W, HPSV Street light fittings with LED fittings of 30W (10 Nos)

0.95 --- 1.05 0.06 --- 0.26

0.03%

13. Replacing Electric storage Water heaters with Solar water heater in canteen application.

2.2 --- 4.87 0.26 --- 1.18

0.13 %

14. Installation of a Boiler steam Air pre-heater in order to balance the plants thermal energy and Electrical energy requirement for efficient operation of Cogeneration system. This activity resulted in elimination of steam venting on account of mismatch between thermal and Electrical energy requirements of the plant.

2.5 --- --- --- 552 28.69

3.1 %

Contd . . .

Sl.No






Power savings

per annum (Units in

Lacs)


annum (MT)



15 Reducing the plant operation days per month from 28.08 days to 26.75 days for achieving the consented production of 450 MT/month by1. Optimising the reaction batch cycle time from 45 min to 40 min by increasing the reactant flow rate without affecting the reaction performance.2. Reducing the batch cycle time of T148 (Tech dissolver) by 15 min. by simultaneous pumping of its feed streams.

0.0 --- 57.99 3.13 14.09

1.4 %

16 Reducing the steam consumption in Formaldehyde plant by optimizing the conversion of Methanol to Formaldehyde in Reactor by reducing the concentration of feed methanol.

0.0 0.299 --- -- 261.1 13.86

1.4 %

17 Reducing the water ingress into the process by automation of Crude Belt Filter cake wash.

0.9 0.179 --- --- 155.64 8.32

0.83 %

Contd . . .

Sl.No






Power savings

per annum (Units in

Lacs)


annum (MT)



18 Reducing Power consumption of Lobe blower for conveying Off gas from Formaldehyde plant to Boiler by reducing the pressure drop across the line.

2.75 -- 16.43 0.89 -- 3.99

0.4 %

19 Increasing the Power generation per MT of steam across the TG (Turbo -Generator) by reducing the pressure drop across the governor valve. (By way of widening the governor opening limits)

0.0 --- --- 1.51 --- 6.8

0.69 %

20 Reducing the Power consumption in ETP aerator by providing VFD with necessary speed control system based on COD level in aerator.

0.9 --- 4.87 0.26 --- 1.18

0.12 %

21 Replacing 150 W, HPSV Street light fittings with LED fittings of 45W (10 Nos)

0.99 --- 0.93 0.05 --- 0.23

0.02 %

Other miscellaneous projects over the past three years (14 projects)

8.76 5.13 108.2 39.143.86%

TOTAL 789.6

29.2 %77.49 2062 460.8

17%

Sl.No






Power savings

per annum (Units in

Lacs)


annum (MT)



18 Reducing Power consumption of Lobe blower for conveying Off gas from Formaldehyde plant to Boiler by reducing the pressure drop across the line.

2.75 -- 16.43 0.89 -- 3.99

0.4 %

19 Increasing the Power generation per MT of steam across the TG (Turbo -Generator) by reducing the pressure drop across the governor valve. (By way of widening the governor opening limits)

0.0 --- --- 1.51 --- 6.8

0.69 %

20 Reducing the Power consumption in ETP aerator by providing VFD with necessary speed control system based on COD level in aerator.

0.9 --- 4.87 0.26 --- 1.18

0.12 %

21 Replacing 150 W, HPSV Street light fittings with LED fittings of 45W (10 Nos)

0.99 --- 0.93 0.05 --- 0.23

0.02 %

Other miscellaneous projects over the past three years (14 Nos.)

8.76 5.13 108.2 39.143.86%

TOTAL 789.6

29.2 %77.49 2062 460.8

17%

IRR 28.1%

INTERNATIONAL NORMS VIS-À-VIS OUR PERFORMANCE

NORMS** ACTUALS -2011-12 PERFORMANCE

Specific Steam consumption (MT) 20 19.56 2.2 %

Specific Power consumption (Kwhr) 2200 1363 38 %

** Norms specified by the Technology provider M/s.Hercules Inc.,USA.

IMPACT ON SPECIFIC POWER / STEAM CONSUMPTION

Details Steam Consumption in MT

Power Consumption in Kwhr

Specific consumption during 1999

25.03 2643

Specific consumption during 2011-12

19.56 1363

A whopping reduction of 22 % in Steam Consumption 48 % in Power Consumption

TREND- SPECIFIC POWER CONSUMPTION

A whopping reduction of 52% in Power Consumption

2750

2400

2150

1825

1363

152115481554

2694

2431

15871695

2850

2643

1929

2200

2090

1489 1421 1391

154015401550

1650

2400

1550

1975

14501380

1510

1200

1400

1600

1800

2000

2200

2400

2600

2800

3000

ACTUALS 2850 2694 2643 2431 2200 2090 1929 1695 1587 1554 1548 1521 1489 1421 1391 1363

TARGETS 2750 2400 2400 2150 1975 1825 1650 1550 1550 1540 1540 1510 1450 1380

96-97 97-98 98-99 99-00 00-01 01-02 02-03 03-04 04-05 05-06 06-07 07-08 08-09 09-10 10-11 11-12

1510

14211450

1391 13801363

1250

1300

1350

1400

1450

1500

1550

2009-10 2010-11 2011-12

TargetActual

TREND- SPECIFIC POWER CONSUMPTION

TREND - SPECIFIC STEAM CONSUMPTION

A whopping reduction of 41.3 % in Steam Consumption

33.30

30.30

27.8027.25

25.03

23.37

21.04

19.18 19.1020.01

19.2019.2519.00 19.0819.81 19.56

29

27 27

2422.75

20.75

18.35

2120 20 20 19.5 19.8 19.6

16.00

18.00

20.00

22.00

24.00

26.00

28.00

30.00

32.00

34.00

36.00

16

18

20

22

24

26

28

30

32

34

36

ACTUALS 33.3030.30 27.80 27.25 25.0323.37 21.04 19.18 19.1020.0119.20 19.2519.00 19.0819.81 19.6

TARGETS 29 27 27 24 22.8 20.8 18.4 21 20 20 20 19.5 19.8 19.6

96-97

97-98

98-99

99-00

00-01

01-02

02-03

03-04

04-05

05-06

06-07

07-08

08-09

09-10

10-11

11-12

19.519.05

19.8 19.81 19.6 19.56

1515.5

1616.5

1717.5

1818.5

1919.5

20

2009-10 2010-11 2011-12

TargetActual

TREND - SPECIFIC STEAM CONSUMPTION

We have commissioned a Zero liquid Discharge systemcomprising of Multiple Effect Evaporator and ATFD leading toincrease in Steam consumption.

18.8 18.6**

Reaction

Crystalliser

Pure Vacuum Crystallizer

Tech Dissolver

TO AIR

PE : Pentaerythritol

Ca

FaAa

Distillation Column

For Formaldehyde and Methanol Recovery

Sodium Formate Drier

Sodium Formate Bagging

TO AIR

Crystalliser Mech Sieving

PROCESS BLOCK DIAGRAM

Knock Down Tank

Stripper Five Effect Evaporator

Crude Vacuum Crystalliser

Crude Belt Filter

Deionizer / Carbon columns

Tech PE Drier

TO AIR

Tech PE Bagging

Tech PE Silo

Mono PE Drier

TO AIR

Mono PE Bagging

Mono PE Silo

Di PE Bagging

Crude Mother Liquor

Di PE Drier

Di PESilo

Bottlenecks

Innovative project – 1Reducing the Plant operating days by optimizing the

cycle time of Batch operations.

Concepts :Increasing the Reaction batches/day by optimizing the Reaction Batch cycle time.Increasing the Mono Pentaerythritol (PE) batches/day by optimizing the processing time.

System:The process of manufacturing of PE starts with a batch reaction involving Formaldehyde, Acetaldehyde and Caustic solutions. By optimizing the batch cycle time of reaction, we could increase the reaction batches/day, thereby reducing the number of plant operating days.In the manufacturing of Mono PE – the batch cycle time of Batch evaporation was optimized by which the number of batches/day was increased.

Activity (A). Optimization of Reaction time:

Conducted Pilot reactor studies.

Sample output analyzed every 5 minutes and compared withstandards.

By increasing the rate of addition of the reactants to theReactor without affecting the kinetics of the reaction, the Reactionbatch cycle time was reduced by 5 minutes per reaction

(Reaction time has got reduced to 40 minutes from 45 minutes).

Necessary controls exercised to prevent the side reactions.

Exothermic reaction was controlled by adequate cooling.

After successful implementation of this project, average Reactionbatches per day got increased to 18.5 from 17.5.



Reactor

P‐101

Acetaldehyde

FormaldehydeCaustic

Before

Reaction Time 45 Mins

CW O/LCW I/L

CHW I/LCHW O/L

Duration in minutes

Chilled water to PHE

10

Cooling water to PHE

35

Reactor

P‐101

After

Reaction Time 40 Mins

Duration in minutes

Chilled water to PHE

15

Cooling water to PHE

25

Acetaldehyde

FormaldehydeCaustic

CW O/LCW I/L

CHW I/LCHW O/L

Activity (A): Optimization of Reaction Batch cycle time

Before After

1 Reaction time 45 min. 40 min.

2 Reaction batches per day 17.64 18.54

3 Penta Production per day 16.03 MT 16.82 Mt

4 Consented Limit 450 MT/month 450 MT/month

5 No of days of Operation 28.08 days 26.75 days



Activity (B). Optimization of Batch evaporation:

By implementing the system of simultaneous pumping of two feedstreams for evaporation, the batch evaporation cycle time has gotreduced by 30 minutes per batch, because of which the number ofbatches per day has got increased.

Flow meters with integrators were installed in both feed streams inwhich the required quantity of feed were set and batch pumpingwas done in auto mode because of which the time delay due tomanual pumping of two streams one by one was eliminated completely.



50%

Before

Pumping Time 30mins

Pumping Time 25mins

20%

80%

Total Filling Time 55mins



Tech Dissolver

Pure Penta Solution Recycled Penta Solution

After

Total Filling Time 30 mins

Tech Dissolver

Pure Penta Solution Recycled Penta Solution

FIT FIT

20%

80%



Activity (B): Optimization of Tech dissolver batch cycle time

Before After1 Feed streams pumping time 55 min 30 min

2 Tech Dissolver Batches per day

4.17 4.50

3 Batch Cycle time 350 minutes 325 minutes

4 Penta Production per day 16.03 MT 16.82 Mt

5 Consented Limit 450 MT/month 450 MT/month

6 No of days of Operation 28.08 days 26.75 days



After

After successful implementation of these projects, the reaction batch cycle time has got reduced by 5 minutes per reaction and the batch evaporation cycle time has got reduced by 25 minutes per batch, resulting in decreased plant operating days from 28.08 days to 26.75 days. Average power consumption/month before implementation: 625902 KWHrAverage power consumption/month after implementation : 599808 KWHrReduction in Specific Power consumption 58 KWHr/TPE (4% reduction)

Power savings achieved:

Power savings achieved per year : 3.13 Lac unitsCost savings achieved per year : 14.09 RL



After

After successful implementation of these projects, the reaction batch cycle time has got reduced by 5 minutes per reaction and the batch evaporation cycle time has got reduced by 25 minutes per batch, resulting in decreased plant operating days from 28.08 days to 26.75 days. Average power consumption/month before implementation: 625902 KWHrAverage power consumption/month after implementation : 599808 KWHrReduction in Specific Power consumption 58 KWHr/TPE (4% reduction)

Power savings achieved:

Power savings achieved per year : 3.13 Lac unitsCost savings achieved per year : 14.09 RL



This project gave scope to seek expansion for Capex enhancement. Presently

EC awaited from MoEF for 24% increase in

production capacity

Innovative project – 2Reducing the steam consumption by optimizing the

conversion of Methanol to Formaldehyde in Reactor by reducing the concentration of feed methanol.

Objective :To reduce the excessive steam consumption in the Re-boiler of Distillation column of Formaldehyde plant by reducing the methanol % fed to Distillation column.

System :Formaldehyde is produced by partial oxidation of methanol over silver catalyst.Air methanol as per ratio is produced in a carburetor and passed over a silver catalyst to produce formaldehyde. The vapor outlet of reactor is absorbed through DM water. Feed methanol concentration is maintained at 84% so as to have excess methanol mixture fed to the reactor.The liquid mixture containing formaldehyde and unreacted methanol is distilled in Dist. Column. Methanol is recycled back to the system.Steam consumption in Distillation column is proportional to the feed Methanol %.

Activity:

Feed Methanol concentration to Carburetor was reduced from 84% to 68% keeping air constant.

Methanol fed to reactor reduced leading to less methanol % at the outlet of reactor.

Steam consumption in Distillation column got reduced due to reduced feed Methanol %.



Air2000 kg/ hr Steam

2000 Kg/hr

Carburetor

84 %Methanol1850 Kg/hr

Reactor Absorber

DM water@ 650 kg/hr

Distillation Column

Recycle methanol to carburetor @ 600 kg/hr

37 % Fa product @ 2500 Kg/hr

3100 Kg/hr

Before :



Air1800 kg/ hr Steam

2000 Kg/hr

Carburetor

68 %Methanol

Reactor Absorber

DM water@ 500 kg/hr

Distillation Column

Recycle methanol to carburetor @ 500 kg/hr

37 % Fa product @ 2500 Kg/hr

3000 Kg/hr

After :

2000 Kg/hr



Advantages…

Before After

1 Methanol Feed concentration 84% 68%

2 Reactor conversion efficiency 60% 70%

3 Unreacted Methanol fed to Distillation column

19% 13%

4 Steam to Distillation Column Re-boiler

2000 Kg/hr 1800 Kg/hr



Objective:

To eliminate the fluctuations in CAC wash water fed to Crude vacuum belt filter (CBF) by automation of wash system.

System :

Crystallized Pentaerythritol (PE) along with Sodium formate (SF) in dissolved state is fed continuously to a vacuum belt filter to separate the PE as cake and SF as mother liquor.The rate of CAC wash determines the purity of PE cake (free from SF contamination).CAC wash rate is controlled manually by monitoring the flow through Rotameter.

Innovative project – 3Reducing the water ingress into the process by

automation of Crude Belt Filter cake wash.

ML to SF section

T-170-2

T-170-3

P 170-1 P 170-2 P 170-3

S 170

Spent wash liquor to Evaporator

Recycled wash

Feed TankT 119

PE cakeT 171

CAC Wash Header

Before :

Feed to CBF

ML

Rotameter

Innovative project – 3Reducing the water ingress into the process by automation of

Crude Belt Filter cake wash.

Constraints faced:

CAC wash elsewhere in certain batch operation in the plant leads to pressure fluctuations in the CAC header leading to flow fluctuations in CBF.

Additional wash requires additional Re-evaporation.

Production capability reduction.



T-170-2

T-170-3

P 170-1 P 170-2 P 170-3

S 170

Recycled Wash

Feed TankT 119

PE cakeT 171

CAC Wash Header

After :

Feed to CBF

ML

MF

FIC

Innovative project – 3Reducing the water ingress into the process by automation of

Crude Belt Filter cake wash.

ML to SF section

Spent wash liquor to Evaporator

Advantages:

Steam savings to the tune of 968 Tons/annum

Consistent cake purity leading to better process stability.

Production capability increased by 1.3%

Before After

1 Average CAC wash rate. 12 lpm 10 lpm

2 Steam consumption forRe-evaporation

720 Kg/hr 600 kg/hr



ENVIRONMENTAL IMPROVEMENT PROJECTSInstalled Methanol and Formaldehyde storage tanks vent collection andrecycling system at a cost of 11.7 RL to eliminate VOC emissionsthrough tank breathing.

Installed a over head spray nozzles in the ash yard to ensure completesuppression of dust at a cost of 4.5 RL. This is in light of the recentCPCB’s recommendations of PM 2.5

Installation of Sophisticated Dust Collecting System to keep the Boilerstack emission SPM levels to less than 50 mg/Nm3.

Contd . . .

ENVIRONMENTAL IMPROVEMENT PROJECTSWe have installed a RO system followed by MEE and ATFD to become aZero liquid discharge unit with respect to liquid effluent. We recyclealmost 90% of the effluent generated. Project cost: 1.3 CrWe have implemented LDAR system to track fugitive and point sourceemissions. Project cost: 4.2 RLInstallation of Rupture disc at upstream of Acetaldehyde bullet safetyvalves. Project cost: 4.3 RLWe have developed Green Belt over more than 45% of the total factoryarea.

Contd . . .

ENVIRONMENTAL IMPROVEMENT PROJECTS

We have replaced the asbestos top roofs of our coal yard and boiler areas which were got damaged during Thane cyclone with environment friendly Powder coated metal sheets.

Contd . . .

Before After

ENVIRONMENTAL IMPROVEMENT PROJECTSOnline VOC meters were procured for monitoring the presence of VOC in process stacks and Ejectors. Portable VOC analyzer was purchased. LDAR study was done internally and by external laboratories like M/s. SGS lab, Chennai. VOC emissions are on lower side.We have installed the Weather monitoring station in our plant and the parameters are being monitored on continuous basis.

Contd . . .

RAIN WATER HARVESTING AT SITE

Contd . . .

Tree plantation

By our Chairman By ISO Auditors

By DEE, TNPCB By Employees

THERMAL ENERGY : -

Total Steam flow from the boiler to the plant is measured using“Pressure & Temperature Compensated” Vortex Steam Flow meter.

Steam flow measurement systems are available for measuringindividual flow to various sections of the plant.

Steam balance is carried out on daily basis and any increase /decrease in steam consumption vis – a – vis production is adequatelyreasoned out.

Yearly steam audit by external competent agency

Steam trap monitoring by external agency

ENERGY MONITORING FORMAT & METHODOLOGY

Daily monitoring format – Thermal Energy


April 2012 Steam Generation MT Water Consumption kL

Penta Steam MT

Water - SteamBalance

Power gen. kW-hr

EB Cons kW-hrPower / MT

SteamStock on hand MT (06:00 hrs)

Coal Receipt MT

Coal Consump. MT

Penta Prod MTDATE SH Steam MT SAT Steam MT DSH Steam MT

Vented Steam MT Hot Cond DM Water

TG DG

01-04-2012 0.00 0.00 0.00 0.00 0.00 50.00 0.00 -50.00 0 2760 0 #DIV/0! 581.67 0.00 0.00

02-04-2012 0.00 0.00 0.00 0.00 0.00 18.00 0.00 -18.00 0 3540 0 #DIV/0! 581.67 0.00 20.00

03-04-2012 227.00 24.50 15.70 2.90 131.00 181.00 251.50 -44.80 13550 1628 32 59.69 581.67 118.03 50.0 20.00

04-04-2012 277.00 38.00 19.40 0.80 248.00 54.00 315.00 32.40 19700 0 100 71.12 649.70 0.00 61.0 32.50

05-04-2012 287.00 39.90 20.00 0.10 270.00 55.00 326.90 21.90 20750 0 52 72.30 588.70 0.00 63.4 12.00

06-04-2012 289.00 42.40 20.20 0.00 271.00 53.00 331.40 27.60 21670 0 60 74.98 525.30 53.33 64.0 15.75

07-04-2012 290.00 43.00 20.20 0.20 265.00 55.00 333.00 33.20 21800 0 0 75.17 514.63 116.92 64.6 14.75

08-04-2012 290.00 44.90 20.50 0.10 265.00 43.00 334.90 47.40 21800 0 0 75.17 566.95 154.04 64.7 14.50

09-04-2012 296.00 40.80 20.60 0.80 270.00 57.00 336.80 30.40 22050 0 136 74.49 656.29 0.00 65.0 15.50

10-04-2012 300.00 37.30 20.80 1.80 253.00 60.00 337.30 45.10 22660 0 56 75.53 591.29 21.89 65.3 19.25

11-04-2012 290.00 37.20 20.20 0.20 263.00 51.00 327.20 33.40 21620 0 72 74.55 547.88 73.47 63.3 13.00

12-04-2012 294.00 39.50 20.50 0.40 104.00 53.00 333.50 197.00 21650 0 104 73.64 558.05 0.00 64.5 13.00

13-04-2012 298.00 41.90 20.50 0.60 300.00 47.00 339.90 13.40 21530 0 68 72.25 493.55 69.70 65.8 14.75

14-04-2012 297.00 42.10 20.80 1.40 300.00 47.00 339.10 12.90 22070 0 0 74.31 497.45 20.40 65.5 15.25

15-04-2012 295.00 43.50 20.60 1.50 300.00 44.00 338.50 15.10 21590 0 0 73.19 452.35 30.96 65.3 13.00

16-04-2012 300.00 44.00 20.80 1.20 300.00 56.00 344.00 8.80 22400 0 268 74.67 418.01 71.92 66.5 19.75

17-04-2012 296.00 40.00 20.60 2.90 300.00 56.00 336.00 0.60 21550 0 600 72.80 423.43 0.00 65.0 17.00

18-04-2012 304.00 41.00 21.50 2.90 323.00 58.00 345.00 -14.50 22340 0 572 73.49 358.43 55.53 66.8 17.00

19-04-2012 303.00 37.60 20.90 4.40 277.00 81.00 340.60 3.50 22010 0 648 72.64 347.16 64.70 66.0 20.25

20-04-2012 314.00 43.50 21.70 2.90 298.00 62.00 357.50 19.20 21750 0 492 69.27 345.86 0.00 69.0 18.75

21-04-2012 303.00 38.50 21.00 2.60 295.00 63.00 341.50 4.50 21850 0 0 72.11 276.86 118.84 65.8 18.75

22-04-2012 303.00 43.60 21.10 1.40 295.00 57.00 346.60 15.70 22000 0 0 72.61 329.90 58.15 66.9 15.00

23-04-2012 304.00 41.10 21.20 2.90 301.00 63.00 345.10 2.30 22210 0 316 73.06 321.15 121.03 66.9 16.75

24-04-2012 306.00 42.00 21.00 4.30 292.00 71.00 348.00 6.00 22390 0 680 73.17 375.28 75.40 67.5 13.50

25-04-2012 306.00 23.50 21.00 4.70 232.00 99.00 329.50 19.50 21470 0 856 70.16 383.18 107.85 63.8 13.00

26-04-2012 316.00 42.50 21.70 2.70 297.00 68.00 358.50 15.20 22800 0 420 72.15 427.23 52.89 69.3 11.00

27-04-2012 315.00 41.00 21.90 2.30 298.00 64.00 356.00 15.90 22400 0 668 71.11 410.82 150.34 68.9 17.25

28-04-2012 320.00 40.30 21.90 5.90 297.00 72.00 360.30 13.20 22700 0 0 70.94 492.26 0.00 69.7 9.00

29-04-2012 319.00 43.00 22.20 2.50 297.00 64.00 362.00 23.20 22550 0 0 70.69 422.56 46.88 70 1.75

30-04-2012 316.00 44.70 22.00 1.40 303.00 64.00 360.70 15.70 22170 0 396 70.16 399.44 79.11 69.8 8.00

TOTAL 8355.00 1121.30 580.50 55.80 7645.00 1866.00 9476.30 545.80 605030.00 7928.00 6596.00 72.42 1661.38 1834.30 450.00

Monthly monitoring format – Thermal Energy


BOILER MONTHLY REPORT April '11 May ' 11 June ' 11 July ' 11 August ' 11 September' 11 October' 11 November' 11 December' 11 January' 12 February' 12 March' 12 2011-12 AVG

STEAM SH steam generated MT 7623.00 7781.00 8563.00 7519.00 7439.00 7432.00 7962.00 8665.00 6573.00 7626.00 8248.90 8031.00 7789

Sat steam generated MT 839.61 935.40 1025.35 996.10 985.70 1018.30 1101.00 1028.76 854.38 1033.75 1210.00 1059.20 1007

LPDSH water spray MT 527.00 539.50 563.90 508.00 505.30 516.40 545.50 586.60 456.30 521.60 575.30 559.40 534

LP steam vented MT 92.60 86.73 50.40 30.70 54.30 58.90 70.90 57.30 35.30 59.40 24.70 21.80 54

Hot condensate consumption MT 7177.00 7564.00 8361.00 7539.00 7176.00 7435.00 6687.00 8460.00 6472.00 7557.00 7900.00 7175.00 7459DM water consumption MT 1803.00 1482.00 1622.00 1383.00 1351.00 1325.00 1149.00 1738.00 971.00 1622.00 1607.00 1656.00 1476

Enthalpy of SH steam kCal/kg 776.00 776.00 776.00 776.00 776.00 776.00 776.00 776.00 776.00 776.00 776.00 776.00 776

Enthalpy of sat steam kCal/kg 667.00 667.00 667.00 667.00 667.00 667.00 667.00 667.00 667.00 667.00 667.00 667.00 667Enthalpy of exhaust steam kCal/kg 707.00 707.00 707.00 707.00 707.00 707.00 707.00 707.00 707.00 707.00 707.00 707.00 707

Enthalpy of feed water kCal/kg 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110

Total water consumption MT 8980.00 9046.00 9983.00 8922.00 8527.00 8760.00 7836.00 10198.00 7443.00 9179.00 9507.00 8831.00 8934

Total steam generated from boiler MT 8462.61 8716.40 9588.35 8515.10 8424.70 8450.30 9063.00 9693.76 7427.38 8659.75 9458.90 9090.20 8796

Penta steam consumption MT 8556.41 8716.40 8776.35 8446.50 8299.30 8300.30 8766.00 8604.76 8505.00 10111.13 9458.90 9090.20 8803

FUEL

Total coal consumption MT 1441.90 1568.50 1810.40 1769.50 1533.60 1550.90 1777.80 1538.90 1600.50 1673.10 1692.20 1621.20 16326000 GCV coal consumption MT 1441.90 850.00 0.00 150.00 752.00 800.00 684.00 1455.10 960.30 501.94 846.10 500.00 745

5600 GCV coal consumption MT 0.00 718.50 1810.40 1619.50 781.60 750.90 1093.80 83.80 640.20 1171.16 846.10 1121.20 886

AFB GCV of 6000 GCV coal kCal/kg 5193.00 5193.00 5193.00 5193.00 5193.00 5193.00 5193.00 5193.00 5193.00 5193.00 5193.00 5193.00 5193

AFB GCV of 5600 GCV coal kCal/kg 4167.00 4507.32 4507.32 4507.32 4507.32 4507.32 4507.32 4370.73 4370.73 4370.73 4370.73 4370.73 4422

Avg GCV of coal kCal/kg 5193.00 4878.90 4507.32 4565.44 4843.54 4861.01 4771.13 5148.22 4864.09 4617.42 4781.87 4624.33 4805Avg coal cost per month Rs / MT 5392 4934 4381 4443 4776 4841 5190 5066 5165 5586 5397 4808 4998

CALCULATIONS

Heat input to boiler kCal 7487786700 7652557317 8160046829 8078550000 7428055024 7538944390 8482115415 7922601617 7784980339 7725400566 8091873398 7496964390 7820822999Heat output from boiler kCal 5544580770 5703163800 6274077950 5562481700 5503408900 5516905100 5915949000 6343909320 4853507660 5654714750 6167737400 5938620400 5748254729Boiler efficiency (Direct) % 74.05 74.53 76.89 68.85 74.09 73.18 69.75 80.07 62.34 73.20 76.22 79.21 73.50

Steam - Fuel ratio 5.87 5.56 5.30 4.81 5.49 5.45 5.10 6.30 4.64 5.18 5.59 5.61 5.39

TG power generated per MT steam kW/MT 72.21 71.97 71.09 72.91 72.79 74.35 75.38 73.86 73.35 73.12 75.55 74.11 73.39Specific steam cons in TG kg/kW-hr 13.85 13.89 14.07 13.72 13.74 13.45 13.27 13.54 13.63 13.68 13.24 13.49 13.63% steam vented to generated % 1.09 1.00 0.53 0.36 0.64 0.70 0.78 0.59 0.48 0.69 0.26 0.24 0.61

Fuel towards power generation MT 136.79 147.66 170.49 165.04 143.04 144.16 165.09 145.03 149.56 155.69 156.16 151.28 152

Fuel towards process applications MT 1305.11 1420.84 1639.91 1604.46 1390.56 1406.74 1612.71 1393.87 1450.94 1517.41 1536.04 1469.92 1479

Heat - Power ratio of power plant 9.09 9.09 9.09 9.09 9.09 9.09 9.09 9.09 9.09 9.09 9.09 9.09 9.09

TG Power Generation cost Rs / kW 1.34 1.30 1.23 1.34 1.26 1.26 1.43 1.15 1.60 1.56 1.35 1.22 1.33

Steam Generation cost Rs / MT 908.64 887.86 903.69 930.71 882.62 904.53 1052.56 905.99 971.91 924.35 965.58 857.49 926.41PENTA Penta production MT 450.00 450.00 450.00 450.00 450.00 450.00 450.00 450.00 450.00 450.00 450.00 450.00 450.00

Specific steam cons by plant MT / MT PE 18.81 19.37 21.31 18.92 18.72 18.78 20.14 21.54 16.51 19.24 21.02 20.20 19.55

Specific power cons by plant kW / MT PE 1347.44 1379.57 1485.94 1351.45 1310.53 1317.28 1429.18 1490.01 1153.85 1274.58 1404.50 1328.11 1356EQUIVALENT FUEL CONSUMPTION

Total coal consumed MT 1441.90 1568.50 1810.40 1769.50 1533.60 1550.90 1777.80 1538.90 1600.50 1673.10 1692.20 1621.20 1632

Avg GCV of coal kCal/kg 5193 4879 4507 4565 4844 4861 4771 5148 4864 4617 4782 4624 4805Boiler efficiency (Direct) % 1 1 1 1 1 1 1 1 1 1 1 1 1

GCV of equivalent fuel kCal/kg 3500 3500 3500 3500 3500 3500 3500 3500 3500 3500 3500 3500 3500

Boiler efficiency with equ. Coal % 1 1 1 1 1 1 1 1 1 1 1 1 1Equivalent coal consumption MT 2139.37 2207.81 2331.44 2308.16 2092.88 2146.36 2420.24 2269.65 2224.28 2207.26 2311.96 2141.99 2240

Specific equ. Coal consumption kg/MTsteam 250.03 253.29 265.65 273.27 252.18 258.59 276.09 263.77 261.53 218.30 244.42 235.64 254

Steam Cost (Coal handling charges not included)Budjeted steam cost Rs / MT 842 842 842 842 842 842 842 842 842 842 842 842 842

Actual steam cost Rs / MT 909 888 904 931 883 905 1053 906 972 924 966 857 925

% Variance wrt budget -7.91 -5.45 -7.33 -10.54 -4.82 -7.43 -25.01 -7.60 -15.43 -9.78 -14.68 -1.84 -9.82

Efficiency is calculated on daily basis by direct method.Belt Weighment scale is fixed in the feed belt conveyor & used formeasuring fuel quantity.Boiler energy audit is carried out once in a year by expert consultants.90 to 95% of hot condensate is returned to boiler.All critical parameters of the captive plant are connected on line toManagers/Executives for effective monitoring through internet.

COGEN PLANT EFFICIENCY

Electrical power tree is prepared to monitor fixed and variable powerconsumption.

KWhr consumption is monitored for overall plant and individualsections and the consumption is compared with production and anyvariation is reasoned out.

Equipment running hours are monitored on daily basis to identifyidle running/under loading of the machineries

Utility report is generated on daily basis which captures specificpower, steam and water consumption.

Any deviation of the specific consumption figures from the “Budget”is captured in terms of LOSS/GAIN in Rupees on daily basis.

ELECTRICAL ENERGY

MODEL ENERGY MONITORING FORMAT

MODEL ENERGY MONITORING FORMAT

Daily Power consumption report

Monthly Power consumption report

Energy week is celebrated in the month of December to emphasize theimportance of energy conservation across the factory.

Energy conservation related ideas received from employees throughsuggestion scheme is evaluated, ideas worth implementing arerewarded with “Energy Efficient Gadgets”

Total no of suggestions received in 11-12 - 22

No of suggestions implemented - 17

On completion of the project, IRR projected and IRR actually realized iscompared.

To improve the awareness on Energy conservation, CFL lamps issued toall daily contact workmen during the safety week celebrationsMarch’2012.

IMPLEMENTATION OF SUGGESTIONS

Replacement of 150W SV lamps with 45 W LED street light fittings.

IMPLEMENTATION OF SUGGESTIONS

Before After

RENEWABLE ENERGY PROJECTS

Installed Natural draft air ventilators on top of Stores, Workshop and Boiler, investment made RL 1.55 and Savings RL 1.7/annum due to stoppage of power driven exhaust fans. Extending the same facility to Coal storage sheds this year.

5% of entire plant roof is converted into transparent PVC sheets, thereby achieving saving of 0.4RL/annum in lighting system.

As an alternate to the coal, we also use Rice husk as a co-fuel in the Boiler.

Contd . . .

RENEWABLE ENERGY PROJECTS

Solar Water heating system to Industrial Dish Washing application in canteen at a cost of RL 2.2, thereby achieving saving of 1.18 RL/annum.

Reduction of throttling losses across TG by Modification of Nozzleplates.Reducing the head pressure of Boiler De-aerator feed water pumps.Installation of VFD for Instrument Air compressor.Power conservation by effluent reduction at source.Reducing the surface moisture of coal by installing Turbo ventilatorsin Coal storage sheds.Replacement of worm gear with inline helical gear for ETP aerator.Replacement of pneumatic level instruments with Electronic type.Installation of Energy Monitoring System.Optimizing the power consumptions of Vacuum pump in Crude BeltFilter.Replacement of conventional Light fittings with LED fittings and Lightpipe.Installation of solar systems for lighting requirements.Continuing with phase wise replacement of standard motors withEFF1 motors.Encourage employees to qualify as Certified Energy Manager/Auditor.

ENCON efforts for future…

Best practices on energy front implemented through our associates

Persuaded the coal suppliers to shift importing of coal from Chennai to a nearby port at Karaikal to reduce transportation distance by 200 KM per trip of truck…. Reduction in Diesel consumption by the trucks.While evaluating the quality of imported coal, special weight age is given for ash and sulphur content though they do not contribute to the ‘heat value’ of the coal. This is based on the environment impact on account of high ash and high sulphur coal usage.Increased the Acetaldehyde tanker capacity from 8MT to 16MT to reduce the number of trips of tanker….Truck movement on this RM supply has reduced by half.We have implemented a system for the vehicles used for other plant works to be completed locally with a predefined schedule thus avoiding frequent vehicle movement.

IMPLEMENTATION OF CORRECTIVE / PREVENTIVE ACTIONS FROM ISO 14001 / OHSAS 18001 CERTIFICATION

Sl.No Standard Description and

ConsequenceCategory of

FindingCorrective

actionsPreventive

Action1 ISO

14001:2004Requirement: ISO 14001:2004 Cl.4.5.3 states that "Actions taken shall be appropriate to the magnitude of the problems and the environmental impacts encountered. The organization shall ensure that any necessary changes are made to environmental management system documentation"Failure: Investigation has not been done for some environment related Non-conformance reported during the recent cyclone.Evidence: The evidences are Physically verified for some location.

Minor/ 4.5.3 EIA impact study will be completed for chemical spillages and damages in hazardous material storage area and scarp yard.

Corrective actions arrived at will be implemented. This aspect has been incorporated in the procedure manual.

2 ISO 14001:2004 / OHSAS 18001

Operational Controls to be improved in the following area in the Pentaerythritol Production Main Control Room (MCR):- Noise emanating from the MCR AC Compressor is on the higher side. Noise level monitoring to be done here since this Compressor is running continuously

Observation/4.4.6

AC compressor area will be included in the Noise survey monitoring area and periodic monitoring of Noise will be done.

Effectiveness is being ensured during internal monthly EHS meeting.

Date of audit: 27.02.2012

Awards and Recognitions….

We have won "The Environmental Best practices Award” for “Most Innovative Environmental project” by CII in Jan’2011

Challenges faced during “THANE” cycloneOur plant got devastated during Thane cyclone on 30th Dec 2011With concentrated team efforts we overcame the challenges and restored the plant to achieve the targeted production.

Before Cyclone

After restoration

EXISTENCE OF HUMAN RACE IS CENTERED

AROUND “ENERGY”

ENERGY IS THE “BREATH” OF INDUSTRY.

THANK YOU !!!

IT CAN NEITHER BE CREATED NOR DESTROYED. BUT CAN BE “CONSERVED”.

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Asian Paints Limited Penta Division Cuddalore

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