aditya birla chemicals (india) ltd. (chemical division) · unit profile aditya birla chemicals...
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First Prize
Chlor-Alkali
ADITYA BIRLA CHEMICALS (INDIA) LTD.
(CHEMICAL DIVISION)
Renukoot (Uttar Pradesh)
Unit Profile
Aditya Birla Chemicals (India) Limited, Renukoot Chemical Division, formerly known
as Kanoria Chemical Industries Limited (KCIL). KCIL stated its production with
Mercury based technology in year 1964. The plant capacity was enhanced in year
2006 and 2008 with installation of 110 TPD each.
The products of the unit are Caustic Soda Lye, Liquid Chlorine, Hydrochloric Acid,
Stable Bleaching Powder, Aluminium Chloride, Poly Aluminium Chloride, and
Chlorinated Paraffin.
Energy Consumption
Item description Unit 2012 – 13 2013 – 14
Electrical Energy kWh/T 2626 2466
Thermal Energy M kCal/T 1.26 1.03
Total Energy Bill Rs Lakh 14219.9 19462
Energy as % of total cost % 62 61
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Energy Conservation Measures Taken
1. Reduction in operating Current Density
In year 2012-13 decision was taken to
replace 120 elements of Generation “IV” with
generation “V-B” at facility Mem-I. In year
2013-14 spare Generation “IV” membrane
realigned in all the three facility. Without
change in production capacity of 365 TPD,
current density at all the three plants were
rationalised which resulted sustained
reduction in the specific Consumption of all
three units.
Investment : Nil
Electricity savings : 155.50 Lakh kWh/Annum
Money saving (including Coal) : Rs. 1,351 Lakh/Annum
2. Energy Consumption at cooling tower
Existing cooling water pumps were replaced by energy efficient pumps with IE-III
motor.
Investment : Rs 16.0 Lakh
Electricity savings : 20.04 Lakh kWh/Annum
Money saving (including Coal) : Rs. 174.24 Lakh/Annum
3. Energy reduction at Chlorine Compression
It was observed that installed chlorine compressors were with higher capacity and
lot energy is getting wasted through recirculation. The optimum utilisation of
Chlorine compressors were achieved by
Facility Previous Current
Mem-I Fixed speed Motor VFD driven Motor with modified SOP
Mem-II VFD running at full speed SOP altered to gain benefits through
altering compressor speed.
Mem-III Operating with Lower
suction pressure and lower
capacity utilization.
SOP altered to operate with higher
suction pressure and better capacity
utilization.
Investment : Rs. 8.2 Lakh
Electricity savings : 8.19 Lakh kWh/Annum
Money saving (including Coal) : Rs. 74.75 Lakh/Annum
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4. Chilled water Pump at Mem –III
Energy consumption at chilled water pumping was
reduced after revisiting chilled water flow and head
demand. Spare pump within the facility is now being
utilised to meet the chilled water demand.
Previous : 215 m3/hr, 48 m head, 45 kW.
Current : 200 m3/hr, 30 m head, 30 kW.
Investment : Nil
Electricity savings : 1.20 Lakh kWh/Annum
Money saving (including Coal) : Rs. 10.56 Lakh/Annum
5. Brine Integration
Initially all the three manufacturing facilities had their own primary brine
preparation system. Revisiting equipment design (operating capacity), process
inefficiency and operating procedures an integrated primary brine preparation were
achieved. This resulted in stoppage many process equipments and significant
reduction in auxiliary consumption. The benefits don’t include gain achieved through
temperature and cell power reduction.
Investment : Nil
Electricity savings : 7.16 Lakh kWh/Annum
Money saving (including Coal) : Rs. 62.24 Lakh/Annum
6. Compressed Air System integration
Air to plant was compressed using three smaller sized air compressors. A study was
performed to evaluate overall plant air consumption, and concluded that air demand
could be catered by a single compressor (with standby) lying unutilized which was
procured with latest facility. This also called for replacing air operated pumps with
motor coupled pump. Major overhauling of compressors were done to ensure
mechanical integrity and taken in line.
Investment : Nil
Electricity savings : 8.34 Lakh kWh/Annum
Money saving (including Coal) : Rs. 72.51 Lakh/Annum