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“ENERGY CONSERVATION EFFORTS AT RCF”

“ENERGY CONSERVATION EFFORTS AT RCF”. By R. P. Sharma, Dy. G.M. TECHNICAL SERVICES RASHTRIYA CHEMICALS & FERTILIZERS LTD. TROMBAY UNIT MUMBAI. R. P. SHARMA, Dy. General Manager, R.C.F. Ltd., Mumbai. MAJOR ENERGY INPUTS. STEAM. ASSOCIATED GAS. ELECTRICITY. FUEL OIL.

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“ENERGY CONSERVATION EFFORTS AT RCF”

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  1. “ENERGY CONSERVATION EFFORTS AT RCF” By R. P. Sharma, Dy. G.M. TECHNICAL SERVICES RASHTRIYA CHEMICALS & FERTILIZERS LTD. TROMBAY UNIT MUMBAI R. P. SHARMA, Dy. General Manager, R.C.F. Ltd., Mumbai

  2. MAJOR ENERGY INPUTS STEAM ASSOCIATED GAS ELECTRICITY FUEL OIL

  3. AVERAGE CONSUMPTION LEVELS AT FULL LOAD

  4. APPROACH TOWARDS ENERGY CONSERVATION REPORTING & REVIEWING ENERGY AUDITS SUGGESTION SCHEMES

  5. METHODOLOGY FOR EVALUATION OF ENERGY CONSERVATION SCHEMES • Is the schemeTechno-Economically viable ? • Is adequate space available for the modification? • Is proven technology available for the proposed scheme ? • Is the scheme adversely affecting plant startups or shutdowns? • Is the extra pressure drop created by modification permissible?

  6. METHODOLOGY FOR EVALUATION OF ENERGY CONSERVATION SCHEMES • Is there a possibility of using some idle equipment within the factory ? • Is the downtime required for modification acceptable ? • Is the recovery of energy in one plant going to increase consumption in other plant/section ? • Is the modification adversely affecting operational reliability ?

  7. TECHANICAL INPUTS REDUCE CORE LOSSES OF TRASFORMERS. MINIMISING AIR CONDITIONG LOSSES. PLUGGING COMPRESSED AIR LOSSES. USE OF ENERGY EFFICIENT LAMPS. REDUCING PRESSURE LOSS IN COMPRESSED AIR SYSTEMS. SIZING OF STEAM HEADERS AS PER ACTUAL STEAM REQUIREMENT. THOROUGH INSULATION SURVEY.

  8. TECHANICAL INPUTS THOROUGH SURVEY OF STEAM TRAPS FUNCTIONING. ANALYSE FOR EXCESS OXYGEN IN ALL FIRED HEATERS. IMPROVING CONDENSATE RECOVERY AT ALL POSSIBLE POINTS. IMPROVEMENT OF POWER FACTOR. INSTALLING ELECTRICAL ENERGY METERS FOR ALL MAJOR ELECTRICAL ENERGY DRIVES TO KEEP CONSTANT CHECK.

  9. TECHANICAL INPUTS • INSTALLING ELECTRICAL ENERGY METERS FOR ALL MAJOR ELECTRICAL ENERGY DRIVES TO KEEP CONSTANT CHECK. • IDENTIFY MAJOR HEAT LOSSES THROUGH FLUE GASES IN STACK. • UTILIZATION OF WASTE HEAT SOURCE AVAILABLE AT ONE LOCATION FOR HEATING OTHER STREAM OF OTHER UNITS. • SAVING OF ELECTRICAL ENERGY BY MAXIMIZATION OF THE OUTPUT i.e. BALL MILL • OPTIMIZATION OF WATER FLOW TO HEAT EXCHANGERS.

  10. MAJOR SCHEMES / SUGGESTIONS IMPLEMENTED (2008-09)

  11. CONTINUED

  12. ENERGY INTENSIVE PROCESSES

  13. ASSOCIATED GAS STEAM ASSOCIATED GAS COMPRESSORS BOILER 3 X 170 TPH 105 ATA/510deg FUEL GAS FEED GAS AMMONIA V 1045 MTPD AMMONIA-I 350 MTPD NH3 UREA 1000 MTPD CO2 AMMONIA TO SUPHALA,A.B.C., NITRIC ACID,ANP PLANT PRODUCT UREA

  14. Ammonia V SCHEMES IMPLEMENTED AT RCF TROMBAY Revamp of Ammonia V plant Reduction in specific energy by 2 MKcal/Mt.NH3 IMPLEMENTED Details of the project are as follows…

  15. The Revamp of Primary Reformer • Replacement of staggered tube lay out with single row tube lay out. The furnace extended on the west side to add one more collector to accommodate required no. of tubes. • Increase in tube size from OD/ID = 143 / 117 to 152 / 129 mm. • Replacement of inlet distributors and pig tails. • Replacement of outlet hot collectors.

  16. The Revamp of Primary Reformer • Installation of combustion air pre-heater in waste heat section in lieu of BFW preheater. • Installation of combustion air blower with dual drive (common with fired steam superheater). • Replacement of burners by forced draft type burners. • Modification of roof and floor along with refractory. • Installation of triple decker catalyst.

  17. Auxiliary steam superheater : Modification and installation of raw gas preheater coil and combustion air pre heater in the waste heat section of ‘Auxiliary steam superheater’ to save fuel. Auxiliary steam superheater burners replaced with forced draft type.

  18. LT Catalyst Temp. Control L.T. guard catalyst volume could not be used fully as the inlet temperatures of LT guard and LT main could not be controlled independently. This problem was solved by modification in Primary Reformer convection zone. BFW pre-heater in primary reformer was replaced by combustion air preheater and this BFW preheater is located in between LT guard and LT main.

  19. M.P. Condensate Stripper Installation of medium pressure condensate stripper in place of low pressure condensate stripper led to following benefits – a. Reduction in ammonical effluent b. Reduction of low pressure steam consumption. Installation of condensing type turbine on this low pressure steam enabled to stop motor driven BFW pump thus saving electricity.

  20. CO2 – Removal / Methanation Modified reformer allowed reduction in steam carbon ratio to 3.2. This reduced available heat of regeneration for CO2 removal section. Below mentioned modifications in CO2 removal section further reduced energy requirement of this section. • Installation of 5 stage flash vessel with mechanical steam compressor. • Installation of hydraulic turbine with generator on rich solution • Replacement of tower packing by high efficiency IMTP or equivalent packing.

  21. CO2– Removal / Methanation • Installation of additional gas/gas exchanger (E311B) • Installation of additional DM water pre-heater for steam generation plant to recover all the heat available with low pressure CO2. Apart from saving steam required for de-aerator in steam generation plant, this modification eliminated all air cooler fans used for this service.

  22. Flare System Installation of new hot flare system in place of cold vent stack as pollution abatement measure. In new scenario where no surplus low pressure steam is envisaged, this may lead to saving due to reduction in low pressure steam requirement.

  23. New Synthesis Compressor Revamp • In this connection following options for the revamp of Synthesis section are also considered - • Modification of synthesis loop by additional converter and Installation of loop boiler. • L.P Condensing Turbine for B.F.W Pump.

  24. AMMONIA-I SCHEME: SPARE MOTOR FOR AMMONIA UNLOADING COMPRESSOR IN AMMONIA STORAGE • EXPENDITURE: Rs. 22 LAKHS • BENEFITS ACHIEVED: UNINTERRUPTED OPERATION OF THE AMMONIA STORAGE FACILITY AND OTHER PLANTS IMPLEMENTED

  25. AMMONIA-I • SCHEME: BATTERY BANK FOR 11 KV SWITCHGEAR • EXPENDITURE: Rs. 3 LAKHS • BENEFITS ACHIEVED: TO MEET THE REQUIREMENT OF NEW 11KV SWITCHGEAR OPERATION, CONTROL AND RELAYING IMPLEMENTED

  26. AMMONIA-I • Scheme: New purge gas line from Ammonia I Plant to NSGP boilers to be used as fuel • Saving: 0.5MKcal/MT of ammonia (Opportune saving) IMPLEMENTED

  27. INDUSTRIAL PRODUCTS

  28. FUEL GAS FEED GAS METHANOL 150 MTPD AMMONIA METHYLAMINES 12 MTPD METHANOL METHYLAMINES

  29. MPNAP • Scheme: Replacing cooling tower pumps of MP Nitric Acid plant with higher capacity resulted in stopping of one pump • Savings in Power 27.45 lakh KwH (Rs. 142.72 lakhs) IMPLEMENTED

  30. HPNAP • Scheme: Cooling tower pumps of HPNA are also kept stopped whenever HPNA plant is shutdown. • Savings in Power 3.51 lakh KwH (Rs. 18.25 lakhs) IMPLEMENTED

  31. Sulphuric Acid Plant • Scheme:Increasing surface area of plate coolers and replacing CW pump with new pump • Savings in Power 2.38 lakh KwH (Rs. 12.38 lakhs) IMPLEMENTED

  32. Sewage Treatment Plant • Scheme:Installation of low capacity sewage pump to replace present high capacity pump • Savings in Power 0.65 lakh KwH (Rs. 3.38 lakhs) IMPLEMENTED

  33. Sewage Treatment Plant • Scheme:Installation of Online DO meter to monitor DO in aeration tank on continuous basis. This has helped in optimizing running of aerators to maintain DO level between 2mg/l to 3 mg/l. • Savings in Power 3.58 lakh KwH (Rs. 18.62 lakhs) IMPLEMENTED

  34. Sewage Treatment Plant • Scheme:Installation of Solar Water Heater resulting in stopping of 2 Electric Water Heaters of 22 kW used to heat water from 40 deg C to 60 deg C for 12 hours per day. • Savings in Power 0.33 lakh KwH (Estimated) (Rs. 1.60 lakhs) • Pay Back Period – 4 Years IMPLEMENTED

  35. Steam Generation Plant • Scheme:Procurement of Online DO meter to monitor DO in aeration tank on continuous basis. This has helped in optimizing running of aerators to maintain DO level between 2mg/l to 3 mg/l. • Savings in Fuel 6.64 lakh KwH (Rs. 34.50 lakhs) IMPLEMENTED

  36. CNA PLANT • Utilization of Excess chiller capacity available in CNA plant for cooling CAN control room. • Savings in Power 0.51 lakh KwH (Estimated) (Rs. 2.65 lakhs) IMPLEMENTED

  37. Power Factor Improvement • Carried out Power factor study at various load centers. • Installed LT & HT capacitor banks at various plants. • Power Factor improved up to 0.98 • Savings- Approx. Rs. 2.4 crores / Year IMPLEMENTED • Additional Capacitor units are being installed to improve power factor up to unity. • Savings: - Expected Rs. 6 crores / Year

  38. Energy Saving Through Tube Light Fitting • Replaced conventional tube light chokes (copper balast 15 w) with electronic chokes (500 nos.) • Saving / fitting – 15 watts. • Energy saving 18000 kwH per year. (Rs. 0.95 lakhs) IMPLEMENTED

  39. Energy Saving With Control Voltage Transformers (CVT) • CVTs used for lighting purpose. • CVT maintains constant voltage resulting in increase of lamp life. • Energy saving 30000 kwH per year. (Rs. 1.56 lakhs) IMPLEMENTED

  40. COMPLEX FERTILIZERS

  41. CO2 AMMONIA PHOSPHORIC ACID ANP NITRIC ACID PLANT PHOSPHORIC ACID PLANT ROCK SUPHALA CONC. NITRIC ACID DIL. H2SO4 SULPHURIC ACID

  42. SUPHALA • Scheme - Interconnection of Process Air Header and Instrument Air Header • Savings in Power 6.64 lakh KwH (Rs. 21.50 lakhs) IMPLEMENTED

  43. SUPHALA • Scheme: One transfer pump is being run for transferring slurry to both RHS & DBN sections instead of two pumps. • Savings in Power 2.21 lakh KwH (Rs. 13.50 lakhs) IMPLEMENTED

  44. “EFFLUENTS CAN BE ASSESTS HOW?”

  45. Liquid Waste Reduction Measures at RCF, Trombay • Recycle of rich effluents in producing plants thus reducing load of ETP. • Recycle of sewage reject water in various operating plant instead of fresh water for floor washings, etc. • Use of Sewage reject water in plants and for horticulture purposes.

  46. Improvements in Nutrient Efficiencies

  47. Improvements in Nutrient Efficiencies

  48. Improvements in Nutrient Efficiencies

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