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KESORAM RAYON A CASE STUDY KESORAM RAYON MANUFACTURER OF - VISCOSE FILAMENT YARN - TRANSPARENT (CELLOPHANE PAPER) - SULPHURIC ACID - CARBON-DI-SULPHIDE - SODIUM SULPHATE EMPLOYEE STRENGTH = 2800 (approx.) TURNOVER (2001-2002) = Rs. 129 CRORES ISO-9002 & ISO-14001 COMPANY LOCATED ON THE BANK OF RIVER BHAGIRATHI, ON 42 HECTARES OF LAND, 60 KM NORTH OF CALCUTTA OUR MAIN PRODUCTS Viscose Filament Rayon Yarn Transparent (Cellophane) Paper STEP-1 NORM FOR ENERGY USAGE Sl. No. - ELECTRICITY - STEAM - WATER Equip- No. No. ment Installed Run RPM Motor Actual Hours KWH/ KW Run Day KW STEP – 2 ELECTRICAL ENERGY Improvement of Power Factor Sizing of motors so as to prevent running on partial load. Soft starters to reduce the energy wastage in high torque applications. Improved alignment, bearing condition. Vibration analysis, vibration monitoring. Contd…. Step -2 (Electrical Energy contd…) Proper sizing of pumps, to avoid throttling of valves and consequent motor size reduction. Use of lumen-efficient light fittings. Deployment of energy efficient motors. Application of frequency inverters for changing speed/flow. On-Off level controllers to prevent continuous run of equipments. THERMAL ENERGY (STEAM/COAL) Increase in combustion efficiency of boilers. Heat recovery from continuous blow down water of boilers. o o Preheating boiler feed water to 105 C/135 C Better condensate recovery. Application of proper design steam traps. Rationalisation of Steam distribution. Minimisation of HP steam usage by converting ejectors to LP steam. Atomisation of Fuel and improvement of calcination dryer. REFRIGERATION Segregation of usage as per temperature requirement. Pipeline sizing to avoid pressure drop. Installation of flow controllers to stop chilled water to equipments, once a predetermined level is reached. Replacement of shell and tube type heat exchangers by plate heat exchangers. Downsize refrigeration area to minimum required. CRITICAL EXAMINATION WHERE HOW MUCH WHEN HOW HOW ELSE WHY STEAM CONDENSATE AIR ELECTRICITY CHILLED WATER STEP - 3 TOTAL SYSTEMS APPROACH SELECTION OF EQUIPMENTS EMPLOYEE INVOLVEMENT INTER UNIT VISITS OPTIMAL CAPACITY UTILISATION UPGRADATION OF TECHNOLOGY ENERGY AUDIT REGULAR MONITORING OF IMPLEMENTED PROJECTS ENERGY AUDIT CONDUCTED BY 1. Tata Energy Research Institute 2. 3. 4. 5. 6. 7. 8. 9. National Productivity Council Balmer Lawrie & Co. Ltd M.K. Raju Consultants (P) Ltd Forbes-Marshall Mazda Croll Reynolds Process Systems Separation Engineers Confederation of Indian Industry (CII) M.K. Raju Consultants (P) Ltd. (for the current year 2002-2003) B.K. BIRLA GROUP OF COMPANIES ENERGY POLICY We shall strive for continuous energy economy through – - Formulation of overall energy strategy and targets. - All round participation of all employees including casual and contractor labours with total commitment from top management. - Improved capacity utilisation. - Upgradation of process, technology and equipment. - Better plant layout. We shall maximise the Group’s synergy by way of sharing expertise, between the units, through inter-unit visits, zonal conference and audit by expert team. As a part of our energy conservation and environmental strategy, we are committed to reduce specific energy consumption by 1% every year by 2010. J.D. PALOD Chairman, Energy Conservation & Productivity Improvement Group B.K. Birla Group of Companies MAJOR ENERGY CONSERVATION PROJECTS IMPLEMENTED YEAR NO. OF PROJECTS IMPLEMENTED TOTAL INVESTMENT RS. LAKHS ANNUAL SAVINGS RS.LAKHS 1994-1995 20 75.27 78.31 1995-1996 17 512.00 183.77 1996-1997 11 123.67 60.95 1997-1998 14 150.61 81.97 1998-1999 30 218.95 127.41 1999-2000 23 180.35 91.06 2000-2001 24 121.85 95.41 2001-2002 27 138.31 98.25 TOTAL 166 1520.99 817.13 TOTAL ELECTRICITY CONSUMPTION (LAKH KWH) 600 591 560 550 540 539 507 500 461 450 434 400 357 350 300 94-95 95-96 96-97 97-98 98-99 99-'00 '00-01 '01-02 TOTAL ELECTRICITY PURCHASED (LAKH KWH) 200 199 180 160 154 138 140 120 100 92 92 79 80 68 71 60 40 20 0 94-95 95-96 96-97 97-98 98-99 99-'00 '00-'01 '01-'02 AVERAGE MONTHLY MAXIMUM DEMAND (KVA) 4500 4336 4000 4011 3730 3500 3126 3000 2621 2548 2500 2600 2000 1940 1500 1000 94-95 95-96 96-97 97-98 98-99 99-'00 '00-01 '01-02 COAL PURCHASED (MT) 90000 85000 80000 75000 70000 65000 84314 60000 81675 85825 81411 78255 73657 74714 55000 50000 57893 45000 40000 94-95 95-96 96-97 97-98 98-99 99-'00 '00-'01 '01-'02 SPECIFIC ELECTRICITY CONSUMPTION (RAYON YARN) 6500 6328 6000 5565 5500 5241 5200 5221 5000 5120 4767 4755 4500 4000 94-95 95-96 96-97 97-98 98-99 99-'00 '00-'01 '01-'02 SPECIFIC ELECTRICITY CONSUMPTION (TP) 3600 3484 3400 3200 3000 2897 2800 2889 2745 2659 2600 2601 2400 2347 2348 2200 2000 94-95 95-96 96-97 97-98 98-99 99-'00 '00-'01 '01-'02 SPECIFIC COAL CONSUMPTION (RAYON YARN) 4.50 4.00 4.47 4.23 3.50 4.13 4.08 3.94 4.03 3.56 3.32 3.00 94-95 95-96 96-97 97-98 98-99 99-'00 '00-'01 '01-'02 SPECIFIC COAL CONSUMPTION (TP) 6.6 6.4 6.5 6.34 6.2 6 5.94 5.8 5.8 5.75 5.69 5.61 5.6 5.61 5.4 5.2 5 94-95 95-96 96-97 97-98 98-99 99-'00 '00-'01 '01-'02 ENERGY CONSERVATION AWARDS NATIONAL ENERGY CONSERVATION AWARDS (a) (b) (c) (d) (e) (f) (g) (h) For the year 1995 For the year 1996 For the year 1997 For the year 1998 For the year 1999 For the year 2000 For the year 2001 For the year 2002 (1st Prize) (2nd Prize) (1st Prize) (1st Prize) (1st & Special Prize) (1st & Special Prize) (Excellence Award) (Excellence Award) Kesoram Rayon Sri J.D. Palod, President, receiving the National Energy Conservation ‘Excellence Award’ for the year 2002, from the Hon’ble Vice President of India. MAJOR PROJECTS IMPLEMENTED IN 2001-2002 SL. NO. PROJECT DESCRIPTION ANNUAL SAVINGS (RS. LACS) INVESTMENT (RS. LACS) 1 SMALLER CAPACITY FEED WATER PUMP FOR BOILER NO.5 5.02 4.00 2 LP STEAM HEATER FOR BOILER NO. 4&5 FOR MAXIMIZING COGENERATION POTENTIAL FOR ADDITIONAL ELECTRICITY GENERATION @ 3200 KWH PER DAY 40.06 20.00 3 PROPER SIZING OF BUSBAR & TRANSFORMER 5.81 3.53 4 INSULATION OF SIDEWALLS OF TP DRYER 3.20 0.85 5 ACID CIRCULATION PUMP FOR DCDA 1.83 2.64 6 AXIAL FLOW TYPE FAN FOR SWITCH HOUSE 0.42 0.90 7 NEW PUMP FOR STRONG LYE PREPARATION 0.17 0.50 8 SOLUTION LYE PUMP REPLACEMENT IN SODA STATION 10 A/B 0.37 0.90 9 TRIMMED IMPELLER FOR SOFTNER FEED PUMP 1.98 0.36 Contd.. SL. NO. PROJECT DESCRIPTION ANNUAL SAVINGS (RS. LACS) INVESTMENT (RS. LACS) 10 PURE LYE PUMP OF STATION NO.16 0.12 0.40 11 AXIAL FLOW FAN FOR PULP GODOWN 0.51 0.90 12 REPLACEMENT OF OLD TRANSFORMERS 2.306 8.48 13 AUTO START & STOP FOR AFT. STATIONS 0.511 1.00 14 THERMO-COMPRESSOR IN PLACE OF LOW EFFICIENCY TG-1/2 0.73 8.00 15 UTILISATION OF 161 M3/DAY SPENT WATER FROM CALCINATIONS TO SPINNING 1.42 0.72 16 SAVING OF FRESH FILTER WATER IN BOILER HOUSE BY USING TP PLANT SPENT WATER IN ESP SLURRY SYSTEM & ASH QUENCHING AREAS TO SAVE 977 M3/DAY 8.64 2.40 17 REDUCTION OF TEXTILE LABORATORY AIR CONDITIONING AREAS 1.52 5.60 18 TWO SPEED MOTORS FOR VISCOSE DISSOLVERS 12.33 36.00 Contd.. SL. NO. PROJECT DESCRIPTION ANNUAL SAVINGS (RS. LACS) INVESTMENT (RS. LACS) 19 COLOUR-80 TUBE LIGHTS IN SPG. & TEXTILE SECTION 2.71 3.83 20 NEW WATER SPRAY PUMPS FOR TEXTILE OLD-CCR AIR WASHER 0.51 0.65 21 REDUCTION OF WATER CONSUMPTION IN OLD AT 0.45 0.50 22 VFD FOR NEW AFT AXIAL FLOW FAN 0.74 1.50 23 AXIAL FLOW FAN FOR OLD AFT 0.64 2.25 24 TEMPERATURE AND FLOW CONTROL IN AFTERTREATMENT 2.24 4.60 25 CONVERSION OF SPINNING MACHINE INTO CLOSED FRP BOX TYPE TO REDUCE ELECTRICITY CONSUMPTION BY REDUCTION OF SPINBATH CIRCULATION AS WELL AS ENVIRONMENT IMPROVEMENT DUE TO LESS HEAT USAGE 0.59 5.00 26 LIGHT WEIGHT POTS FOR 8 MACHINES 2.33 21.12 27 REDUCTION IN WEIGHT TO TAKE UP CUP 0.14 0.74 TOTAL 98.25 138.31 ENERGY CONSERVATION MEASURES FOR 2002-2003 Sl. No. ENERGY CONSERVATION MEASURES ANTICIPATED SAVINGS/YEAR IN ENERGY VALUE INVESTMENT RS. IN LAKHS LAKH KWH MKCAL RS.IN LAKHS 990 26.19 100.00 01 NEW VAPOUR ABSORPTION HEAT PUMPS IN ENGINE ROOM 3.95 02 USE OF FURNACE OIL IN PLACE OF LDO IN SOLID WASTE INCINERATION - 1.50 1.80 03 LOW CAPACITY TP SPINBATH PUMP 0.55 2.19 2.19 04 LOW CAPACITY PUMP FOR CS2 MELTER 0.05 0.22 0.90 05 CF LAMPS IN PLACE OF INCANDESCENT TYPE 0.30 1.19 2.00 06 HIGH EFFICIENCY VERTICAL RIVER PUMPS 0.75 3.00 3.00 07 VARIABLE FREQUENCY DRIVE FOR RIPENING AIR WASHER FAN 0.23 0.91 1.50 08 DRYER INSULATION BOX 0.84 1.00 09 AFTERTREATMENT SUMP PUMP 0.29 1.17 3.15 10 TIMER FOR EXHAUST FAN 0.09 0.38 0.20 11 REPLACEMENT OF QC EXHAUST FAN 0.08 0.32 0.25 37.91 115.99 TOTAL - 321 ENERGY CONSERVATION MEASURES FOR 2003-2004 Sl. No. ENERGY CONSERVATION MEASURES ANTICIPATED SAVINGS/YEAR IN ENERGY VALUE INVESTMENT RS. IN LAKHS LAKH KWH MKCAL RS.IN LAKHS POWER PLANT REVAMPING AND RATIONLISATION OF BOILER & TURBINE 19.71 108610 705.02 1703.00 02 SPINNING POT SPRAY SYSTEM MODIFICATION 0.08 0.35 0.20 03 ACID CIRCULATION PUMP FOR DCDA 0.13 0.51 2.80 04 TEMP. & STEAM FLOW CONTROLLER IN AFT DRYER 2.24 4.60 05 HOTWELL PUMP FOR TP COOLING TOWER 0.65 2.63 2.50 06 CARBON FIBRE POTS FOR 8 MACHINES 0.58 0.14 0.74 07 UPGRADATION OF ILLUMINATION SYSTEM 7.10 10.50 28.00 721.39 1741.84 01 TOTAL - 544 - ENERGY CONSERVATION TARGET SPECIFIC POWER CONSUMPTION (KWH/TON) ACHIEVED IN 2001-2002 2002-03 2003-04 2004-05 RAYON YARN 4755 4500 4400 4350 TRANS. PAPER 2348 2200 2150 2100 SULPHURIC ACID 47 45 44 44 SODIUM SULPHATE 125 120 119 119 SPECIFIC THERMAL ENERGY CONSUM-PTION (MKCAL/TON) ACHIEVED IN 2001-2002 TARGET FOR TARGET FOR 2002-03 2003-04 2004-05 RAYON YARN 15.66 14.50 14.25 14.00 TRANSPARENT PAPER 25.30 24.50 24.00 23.50 SODIUM SULPHATE 1.50 1.40 1.35 1.30 A FEW CASE STUDIES STATIC INVERTOR IN PLACE OF ROTARY MGSET CONVERTORS (Exhibit – 1) EARLIER SYSTEM - MG-SET SPINNING POTMOTOR SUPPLY FREQUENCY = 123 TO 130 C/S ROTORY CONVERTORS RATING = 2000 KVA PRESENT SYSTEM - INVERTOR FOR HF ELECTRICITY CONSUMPTION OF MGSET = 39000 KWH/DAY ELECTRICITY CONSUMPTION WITH INVERTORS = 33000 KWH/DAY INVESTMENT = RS. 290 LAKHS COUNTER FLOW COOLING TOWER FOR POWER PLANT (Exhibit – 2) APPROACH TEMPERATURE 4 TO 50C APPROACH TEMPERATURE 0.50C TO 10C RESULTED IN INCREASE OF CONDENSOR VACUUM AND REDUCTION IN STEAM CONSUMPTION INVESTMENT = RS. 60 LAKHS ANNUAL SAVING = RS. 55 LAKHS HEAT PIPE HEAT EXCHANGER FOR TP-DRYER (Exhibit – 3) EARLIER SYSTEM - FRESH AIR, HEATED THROUGH STEAM COILS CIRCULATE TO DRYING CHAMBERS, MOIST VAPOUR OF DRYER EXHAUSTED TO ATMOSPHERE AT 930C PRESENT SYSTEM - HEAT PIPE HEAT EXCHANGER DEPLOYED TO PREHEAT INLET AIR BY EXHAUST AIR OF DRYER HEAT RECOVERED INVESTMENT ANNUAL SAVING = = = RS.2,40,000 KCAL/HOUR RS. 30 LAKHS RS. 26 LAKHS VFD FOR ACID PLANT ROOTS BLOWER (Exhibit – 4) - 7000 NM3/HR - 5000 NM3/HR FOR 50 TPD CAPACITY OF ROOTS BLOWER AIR FLOW REQUIRED AIR FLOW CONTROL THROUGH DAMPER & BYPASS INVESTMENT ANNUAL SAVING AIR FLOW CONTROL THROUGH VFD = = RS. 26 LAKHS RS. 24 LAKHS WASTE HEAT RECOVERY OF ACID PLANT (Exhibit – 5) H2SO4 OF 950C REQUIRES TO BE COOLED TO 650C FOR PROPER ABSORPTION EARLIER SYSTEM CI CASCADE COOLERS, WHERE WATER IS SPRAYED FROM TOP & ACID COOLED. WATER DRAINED CONTINUOUSLY. PRESENT SYSTEM PLATE COOLER TO EXTRACT HEAT & UTILISE IN RAYON PLANT, THROUGH INTEGRATION OF SUB-SYSTEMS. SYSTEM INTEGRATION PRESENT SUB – SYSTEMS (Exhibit – 5) Steam LP Steam Heater Rayon Prewash 450 gpm water Rayon Final Wash 400 gpm To drain Water To ETP Condensate H2SO4 at 700C Water ACID COLLER H2SO4 at 900C To drain SYSTEM INTEGRATION RE-ENGINEERED SYSTEM (Exhibit – 5) RAYON FINAL WASH Water at room temp. RAYON PREWASH ACID COOLER H2SO4 PLANT H2SO4at 90o C Water at 70o C INVESTMENT SAVINGS - RS. 45 LAKHS - RS. 4.7 LAKH KCAL/YEAR - 3200 CM WATER/DAY PAYBACK - 21 MONTHS SULPHUR RECOVERY PLANT (Exhibit – 6) EARLIER SYSTEM - PRESENT SYSTEM - INVESTMENT ANNUAL SAVING TAIL GAS OF CS2 REACTORS SCRUBBER FOR H2S, TRACES OF CS2 USING NaOH OF 14.5 TONS/MONTH. RESULTANT Na2S – TREATMENT IN ETP RECOVERY OF SULPHUR OF 300-400 KG PER DAY - RS. 46.00 LACS RS. 18.00 LACS REDUCTION IN AIR CONDITIONING VOLUME (Exhibit – 7) FALSE ROOFING TO REDUCE HEIGHT FROM 22 FT TO 12 FT IN RIPENING ROOM & LAB. REDUCTION IN VOLUME REFRIGERATION LOAD REDUCED - 14260 CFT - 12 TR ANNUAL SAVING INVESTMENT - RS. 2.10 LACS - RS. 5.60 LACS THERMO COMPRESSOR (Exhibit – 8) BEFORE STEAM HEADER 17.5 KG/CM2, 3700C TURBINE-1 0.65 MW TURBINE-2 0.65 MW TURBINE-3 1.5 MW PRDS LP HEADER (2.5 KG CM2) TO PROCESS 2.2 KG/CM2) STEAM HEADER 17.5 KG/CM2, 3700C TURBINE-3 1.5 MW (2.5 KG/CM2) TO PROCESS TO PROCESS (14 KG/CM2) TO PROCESS AFTER PRDS (2.2 KG/CM2) TO PROCESS (14 KG/CM2) THERMO COMPRESSOR (Exhibit – 8) STEAM SUPPLIED BY TG-1/TG-2 PRESENT POWER OUTPUT - 5.6 TPH(2.5 KG/CM2, 2600C) 5600X24 - 6110 KWH/DAY 22 STEAM USED BY THERMO COMPRESSOR 3.64 TPH OF 2.2 KG/CM2 1.96 TPH OF MOTIVE STEAM, AT 14.0 KG/CM2 PROPOSED POWER GENERATION FROM TG-3 3640X24 = 6240 KWH/DAY 14 REDUCTION IN MANPOWER COST, MAINTENANCE COST INVESTMENT ANNUAL SAVING = RS. 2.00 LACS = RS. 1.90 LACS L.P.STEAM HEATER WATER (PREVIOUS) (Exhibit – 9) 400C DEAERATOR BOILER 1000 C TURBINE STEAM 3700C 17.5 KG/CM2 PROCESS 750 KCAL/KG HEAT GAINED FROM 40 TO 750 KCAL/KG L.P. STEAM HEATER (PRESENT) (Exhibit – 9) WATER 400C DEAERATOR LP HEATER 100 0 C BOILER 1250C TURBINE STEAM 3700C 17.5 KG/CM2 750 KCAL/KG TO PROCESS 646 KCAL/KG 2.0 KG CM2 L.P. STEAM HEATER (Exhibit – 9) EXTRA STEAM PASSING THROUGH TURBINE GENERATES 2690 KWH/DAY INVESTMENT OF PROPOSAL ANNUAL BENEFIT - RS. 20.00 LACS - RS. 18.60 LACS USING PLANT SPENT WATER IN BOILER ASH QUENCHING (Exhibit – 10) EARLIER SYSTEM • FRESH FILTER WATER WAS USED FOR BOILER ASH HANDLING SYSTEM @ 60 M3/HOUR PRSENT SYSTEM • T.P.PLANT WASTE WATER IS NOW USED FOR THE SAME INVESTMENT ANNUAL SAVING - RS. 2.4 LACS - RS. 7.2 LACS PROPER SIZING OF BUSBARS & TRANSFORMERS (Exhibit – 11) - REPLACEMENT OF TRANSFORMER RELOCATION OF TRANSFORMER REDUCTION OF JOINTS IN BUSBAR OF CARBON-DI-SULPHIDE REACTORS PREVIOUS PRESENT TRANSFORMER FULL LOAD CU & FE LOSS 10.34 KW 6.37 KW LOAD DISTANCE 750 MTR 400 MTR CABLE LOSS 10.60 KW 5.60 KW 68 38 34 KW 19 KW 54.90 KW 30.97 KW NO. OF JOINTS POWER LOSS DUE TO JOINTS TOTAL LOSS INVESTMENT ANNUAL SAVINGS - RS. 23.00 LACS - RS. 8.30 LACS ILLUMINATION EFFICIENCY (Exhibit – 12) • 36 WATT SLIM TUBE LIGHTS • HIGH EFFICIENCY – CU CHOKES/ ELECTRONIC CHOKES • LIGHTING TRANSFORMERS • 70W/ 120W SON LAMPS FUTURE PROPOSAL TO REPLACE 3700 TUBE LIGHTS - BY 28 WATT FITTING - BY CFL LAMPS TO REPLACE 220 SON LAMPS - BY 45W CFL LAMPS PROPOSED INVESTMENT PROJECTED ANNUAL BENEFIT - RS.28.00 LACS - RS. 10.5 LACS CARBON FIBRE SPINNING POT (Exhibit – 13) No. of Spinning Machines 52 No. of Pot Motors 6880 Power consumption per Motor 190 WATTS Weight of Steel Reinforced Spinning Pot 2.6 Kg Weight of Carbon Fibre Reinforced Pot 2.2 Kg Power consumption reduction 10 WATT Annual Saving 5.89 Lac KWH VAPOUR ABSORPTION HEAT PUMPS (Exhibit – 14) EXISTING PROPOSED ACTUAL MACHINE RATING 170 TR/MACHINE 510 TR FOR 3 MACHINES 275 TR/MACHINE 550 TR FOR 2 MACHINES COOLING WATER REQUIREMENT 365 CM/HR PER MACHINE 290 CM/HR PER MACHINE NUMBER OF MACHINES RUN 1 M/C FOR 1 MONTH 2 M/CS FOR 8 MONTHS 3 M/CS FOR 3 MONTHS 1 M/C FOR 2 MONTHS 2 M/C FOR 10 MONTHS VAPOUR ABSORPTION HEAT PUMPS (Exhibit – 14) SAVINGS POWER STEAM MAINTENANCE TOTAL SAVINGS INVESTMENT - RS. 15.78 LACS - RS. 8.64 LACS - RS. 8.00 LACS - RS.32.42 LACS - RS. 100 LACS POWER PLANT (EXISTING ARRANGEMENT) (Exhibit – 15) TOTAL POWER GENERATION COAL CONSUMPTION - 115026 KWH/DAY 211 TPD(B-GRADE) POWER PLANT (PROPOSED ARRANGEMENT) (Exhibit – 15) TOTAL POWER GEN - 124549 KWH/DAY COAL CONSUMPTION - 185 TPD ( D/E GRADE) INVESTMENT - RS. 1703 LACS ANNUAL BENEFIT - RS. 705 LACS A BIG THANK YOU