1

PresentationFor

11th CII National Energy Award 2010

Reliance Industries LimitedDahej Manufacturing Division, India

BySh Dipak Mehta

Sh Paresh Vasava

Sh Yusuf Husain

KarmabhumiKarmabhumi

2

FTotal Area of 609 hectares having 300 hectares Green belt

FCaptive jetty- capacity for 6000 DWT vessel

FManufacturing facilities of Ethylene, Propylene, EO,

MEG,HDPE, PVC, EVA, VCM, Caustic & Chlorine

F India's Only Salt to PVC Integrated Petrochemical Complex

FCaptive Power generation capacity 155 MW

FCaptive Steam generation capacity 540 MT/Hr

FGas based Power and Steam generation

F9 MGD of surface water from River Narmada (68 KM)

Site ProfileSite Profile

Salt

Ethylene from

BarodaComplex

Semi-RichGas from

GAIL at Gandhar& Hazira

GasCrackerPlant

REON(250KTA)

EO (10 KTA)

Raw Material

C2C3

EPRU

Cl2

EO-EG Plant

VCM Plant

PVC Plant

Chlor-AlkaliPlant

C2H4

HDPE1 PlantRELENE

(200 KTA)

MEG(188KTA)

Caustic Soda Lye

(165 KTA)

30% HCl(15 KTA)

Propylene(100 KTA)

Plants

Imported Propane

Caustic Soda Flakes

(50 KTA)

Lean Gas to GAIL

Products

HDPE2 Plant

EVA PlantEVA (14 KTA)

Integrated OperationIntegrated Operation

India's Only Salt to PVC Integrated Plant

3

Certification & BenchmarkingCertification & Benchmarking

Standards Certification Date System

ISO 9001 – 2008 16th Oct 2009 Quality Management System

ISO 14001 – 2004 16th Oct 2009 Environment Management System

OHSAS 18001 - 2007 16th Oct 2009 Occupational Health and Safety Assessment Series

Plant Year Benchmarking done by Level Remarks

GCU 2009 Solomon, USA Global Ranked 1rd Quartile amongst the 30 participating plants

CPP & utilities

2009 Internal Group sites

Ranked 5th in Internal Benchmarking of RIL Group Sites

MEG 2008 PDC Netherlands Global Ranked 9th amongst MEG industries in the world.

PVC 2007 PDC Netherlands Global Ranked 4th position based on energy consumption in world

Our MissionTo be the lowest specific Energy Consumer in the industry we operateTo Minimize impact on environmentTo Widen our energy sources

Integrating energy management Upgrading Hardware and deploying new technologiesSupporting scientific researchCarrying out Audits & training of employeeBenchmark ContinuouslyPromote Awareness

Plans to achieve by

ENERGY MANAGEMENT POLICYENERGY MANAGEMENT POLICY

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7 of 44

2007: Five Star Rating of BSC Audit2007: Five Star Rating of BSC Audit

2002: CSE Five Leaves Award to Chlor Alkali Plant2003: ISO 9001:2000, ISO 14001:2004, OSHAS 18001:1900 Certification

2004: GAIL Award for Gas Conservation2005: 1st Prize in BEE National Energy Conservation Award

2005: Three Star Rating of BSC Audit

1996: Commercial Production Started Phase - I1999: Commercial Production Started Phase - II

2006: CII Award of Excellence in Energy Efficiency

P

P

JOURNEY OF RIL, DMD.

2006: Certificate of merit by BEE 2006: Certificate of merit by BEE

2008: CII Award of Excellence in Energy 2008: CII Award of Excellence in Energy ManagementManagement

2009: RBNQA Performance Excellence Trophy2009: RBNQA Performance Excellence Trophy2009:2009:CICIII Water Conservation AwardWater Conservation Award

P

P

P

P

P

P

P

P

P

P

P

P

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2009: 2009: GreentechGreentech Environment ExcellenceEnvironment Excellence && Safety Safety Award Award

2009: ICC Energy Management Award2009: ICC Energy Management Award

2008: CII Award of Excellence in Water Management2008: CII Award of Excellence in Water Management

P

2009: Four Star2009: Four Star for BSC Environment Auditfor BSC Environment Audit

STRATEGIC LEVEL

ñSite Presidentñ Sr. Vice President ñ Utility Cell AVPñ Utility Managers

TACTICAL LEVEL

ñ Energy Coordinatorsñ TLS Engineersñ Operation Engineer

SUPPORTING LEVEL

ñ ProcessTechnicianñ Maint. Technician

Major FunctionMajor Function : : Set TargetsProvide directionBenchmarking &External AuditsReview Utilityconsumption trendReview status of ENCON schemes and CDM

Major Function : Identification ofschemeBrainstormingSuggestionScheme

Employee & Vendor InvolvementAwarenessProgrammes

Major Function :

Evaluation ofsuggestion scheme

Monitoring SpecificUtility Consumption

Conceive new and implement schemes

Optimize utilities Consumption

Employees Involvement in Energy ManagementEmployees Involvement in Energy Management

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Planee Obtain Insight (Audits)ee Nominate Energy Champion ee Develop Programsee Set Targets & Measuresee Develop Action Plan

Doee Implement Projectee Monitor Progressee Lock In The Gainsee Set New Targetse Communicate

Results

Checkee Review Resultsee Verify Effectivenessee Examine Opportunitiese For Continual Improvement

Actee Correct Deficienciesee Review Originalee Energy Policiesee Review Objectives &

Targetsee Review Energy Programee Update Action Plan

PD

CA

ENERGY MANAGEMENT PLANENERGY MANAGEMENT PLAN

MONITORING REPORTING SYSTEMMONITORING REPORTING SYSTEM

Video Conference with Corporate Office Top Management. Site Energy Report to bring out salient points related to energy consumption

Plant performance & energy consumption report & reviewby VP ( Technical Services)

Plant-wise report & monitoring for fuel/utilities usage by respective plant heads along with Technical service engineer

On-line monitoring tool IP-21(ASPEN PLUS) :Monitoring of Power, Steam and fuel

6

41

9

16

16

No of projects

18

0

10

8

No of Projects

with Zero Investment

8.1730.3320.662009-10

409.51

4.63

17.55

Savings achieved

(Rs. Crore p.a.)

2.37

0.80

1.26

Payback

(Months)

80.83Total

1.842008-09

Year Investment made

(Rs. Crore)

2007-08 0.33

SAVINGS IN LAST THREE YEARSSAVINGS IN LAST THREE YEARS

Eighteen Schemes were with zero investment with savings of

24.85 crores.

CO2 emission reduction achieved through various schems

in last three years is 64511 MT.

2.412.442.45

2.65

2.502.56

2.87

22.12.22.32.42.52.62.72.82.9

3

2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10

Energy Index MMkcal/MT

ENERGY INDEX OF COMPLEXENERGY INDEX OF COMPLEX

Result of Consistent Efforts of RIL-DMD team

16.03 % Reduction

as compare to 2003-04

16.03 % Reduction

as compare to 2003-04

7

SPECIFIC THERMAL ENERGYSPECIFIC THERMAL ENERGY

0.911.001.05

1.28

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

2006-07 2007-08 2008-09 2009-10

MMKcal/MT

28.9 % Reduction

as compare to 2006-07

28.9 % Reduction

as compare to 2006-07

Contribution of various ENCON schemes

SPECIFIC ELECTRICAL ENERGYSPECIFIC ELECTRICAL ENERGY

1435

1457

15191491

1320

1370

1420

1470

1520

1570

2006-07 2007-08 2008-09 2009-10

KWH/MT

323315

313307

290

300

310

320

330

2006-07 2007-08 2008-09 2009-10

KWH/MT

Chlor alkali plant is consuming almost 45-55 %

of total power consumption of complex.

Chlor alkali Power specific Power increases with

increase in membrane Life

Based on cost benefit analysis we have replaced

the membrane in June 2009

Chlor Alkali Plant Specific Power Consumption Rest Plants Specific Power Consumption

In last four years total 9372 MWH of

power saved through various Energy

Conservation schemes

4.95% reduction of specific Electrical

Energy as compare to 2006-07

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PROJECT

OF

PROVISION OF GAS - GAS EXCHNAGER

BEFORE PROJECT

PLAN

9

DO

AFTER PROJECT

Observations After Commissioning of New Exchanger

0.764MT/HrSteam Savings

58.6677MT/DayTotal Steam Consumption

Parameter UoM Before After

Steam consumption MT/Cycle/Day 38.50 29.33

Number of regeneration cycle

No 2 2

CHECK

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CONCLUSIONSCONCLUSIONS

• Resulted in Energy savings of 0.39 MMkcal/Hr

• Saved Rs 60 lakhs/Yr

• Invetment of project is Rs 24 lakhs

• Payback – 4.8 months

ACT

PROJECT

OF

REDUCTION IN ENERGY DEMAND OF VCM COLUMN

11

FEED

BTM

TOP

VCM Column

VCMEDCHeavy by-products

VCM (high purity)

EDCHeavy by-products

Tray 40

COLUMN DIAGRAMCOLUMN DIAGRAM

1. Model VCM column in Aspen Plus2. Validation based on Licensor’s process

flow diagram3. Fine tuning based on present operating

parameters4. Sensitivity study 5. Trial plan based on optimized window

PLAN

12

0

20

40

60

80

100

120

140

160

180

0 10 20 30 40 50 60 70 80

Tem

pera

ture

(Deg

C)

Stages

Actual Temperature, & Aspen Temp Vs No. of stages

AspenTemp Actual Temp

Column temperature profile: Good match for Aspen Plus model and actual dataValidation – Temperature Profiles

DO

6 0.38 1.878 4.17 0.9990 0.99806 0.39 1.897 4.22 0.9991 0.99826 0.4 1.914 4.25 0.9992 0.99846 0.41 1.931 4.29 0.9993 0.99866 0.42 1.9488 4.33 0.9995 0.9987

5.9 0.38 1.8729 4.16 0.9990 0.99805.9 0.39 1.8894 4.20 0.9991 0.99825.9 0.4 1.9062 4.24 0.9992 0.99845.9 0.41 1.9233 4.27 0.9993 0.99865.9 0.42 1.94 4.31 0.9995 0.9987

5.8 0.38 1.8644 4.14 0.9990 0.99815.8 0.39 1.881 4.18 0.9991 0.99815.8 0.4 1.8979 4.22 0.9992 0.99855.8 0.41 1.9152 4.26 0.9994 0.99865.8 0.42 1.9327 4.29 0.9995 0.9987

Sensitivity Analysis

Reflux ratioPressure at top

(kg/cm2g)Top VCM (Mass Fr)

Bottom EDC (Mass Fr)Steam (MT/hr)

Reboiler Duty (MMKcal/hr)

Plant Operating Condition

DO

13

Optimized Operating Window

Top Pressure

Reflux Ratio

Reboiler Duty Steam

Top(VCM)

Bottom(EDC)

PotentialSteam Saving

Potential Saving

kg/cm2g MMKcal/hr MT/hrMass

FractionMass

FractionMT per

yearRs Lakhs Per year

6 0.42 1.9488 4.33 0.9995 0.9987 2293.173 13.50

5.6 0.37 1.831 4.07 0.9991 0.9982

Aspen Plus model based analysis

DO

Feed flow

Reflux flow

Product flow

Steam flow

Top pressure

Reflux ratio

Energy to reboiler

m3/hr m3/hr m3/hr kg/hr kg/cm2gMMkcal/

hr

Normal Operation

53.84 10.64 25.47 5270 6.00 0.42 2.39

After simulation implementation

54.11 9.60 25.34 4901 6.00 0.38 2.22

Higher capacity operation (120% of normal)

64.50 10.50 30.56 5607 6.00 0.37 2.55

Model recommendations implemented in operations

CHECK

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CONCLUSIONSCONCLUSIONS

• The simulation model predictions were highly accurate

• Optimized VCM column reflux ratio:– Energy savings of 0.17 MMKCal/hr– Saved Rs 13.5 Lakhs per annum – No capital investment

• Increased production rate 120% – Increased feed 10.3 tonne/hr.– Equivalent to increased VCM production of 2 tonne/hr– Total revenue increase of Rs 56.25 Crores / yr (VCM)

ACT

PROJECT

OF

Reduction in energy demand of propylene refrigerant machine

15

29/

Ethylene Tower

75 m tall125 trays

Scope:

•Ethylene tower reboiler and condenser are a major consumers of propylene refrigeration (C3R) –consume more than 60% of total refrigeration.

•Aspen Plus simulation model of the ethylene tower (with peripherals) and C3R 5- stage refrigeration circuit was developed.

PLAN

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1. Model Ethylene Tower in Aspen Plus2. Validation based on Licensor’s process

flow diagram3. Fine tuning based on present operating

parameters4. Sensitivity study 5. Trial plan based on optimized window

PLAN

Validation of ModelValidation of ModelAspen Vs Design Temperature Profile

-40

-35

-30

-25

-20

-15

-10

-5

0

1 11 21 31 41 51 61 71 81 91 101 111 121

Stage

Tem

p, °C

Aspen temperature prof ile Design temperature prof ile

DO

17

33/

28

28.5

29

29.5

30

30.5

31

31.5

32

32.5

33

33.5

0 10 20 30 40 50 60 70 80 90 100Feed tray location

Tota

l Ene

rgy(

MM

kcal

/hr)

Feed tray sensitivity

Lowest total energy consumption observed for feed on Tray 73

DO

34/

UoMSimulation

Results

(80th Tray)

Simulation Results

(76th Tray)

Feed flow TPH 83.4 83.4

Reflux flow TPH 252 246

Product flow TPH 52 52

Energy to reboiler MMkcal/hr 8.4 7.9

Energy to side reboiler

MMkcal/hr 6.45 6.45

Energy to condenser MMkcal/hr 21.04 20.52

Ethylene Product purity

Mole % 99.96 99.96

Top pressure kg/cm2g 17.5 17.5

• Theoretical best feed location is Tray 73, but does not have a nozzle• Use existing nozzle on Tray 76

DO

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Optimized Operating Window§ Column was originally equipped with alternate feed tray

location (Tray 76), no capital investment required

§ Simulation results show that energy requirement for the column is lower on Tray 76. A trial was planned and the feed tray location of the column was changed.

CHECK

Parameter UoM Before After

Ethylene tower reflux T/hr 259 251

C3R 1st stage suction flow T/hr 262 255

C3R 2nd stage discharge flow T/hr 88.5 84.6

Steam to the C3R turbine T/hr 80 79

CONCLUSIONSCONCLUSIONS

• Ethylene tower feed tray optimization:– Reflux flow reduced from 259 TPH to 251 TPH

– C3R turbine VHP steam reduced by1000 kg/hr

• Energy savings:– 0.5 MMKcal/hr

– Rs 72 Lakhs per annum

– No capital investment.

ACT

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CDM AND CCX PROJECTS SUMMARYCDM AND CCX PROJECTS SUMMARY

6

9

6

Payback

month

1410

1300

436

Savings

(Rs Lakhs)

744

970

220

Investment (Rs Lakhs)

CCX42000 (VER)

Utilization of excess Hydrogen generated by CA plant in CPP boiler

03

Utilization of Excess Steam in VAR of PVC Plant

02

Utilization of Process Steam in VAR of MEG Plant

Project description

27342

(CER Issued)

Total CO2 Reduction

(MT)

CDM

01

Type of project

Sr No.

CDM and CCX INITIATIVES

• Air pollution control for flue emission (e.g. Low Sulphur Fuel, Low NOx

burner, Steam/Water injection for low NOx)

• All waste chlorine is diverted to ‘Hypo unit’ in Chlor alkali plant

• Closed loop flaring system Adequate height of Flare & Boiler Stacks to

ensure minimum GLC

• Installed system for VOC control mechanical seals in pumps which

handles hazardous material / closed loop sampling / on line PPM/LEL

Detectors

• LDAR Programmes for fugitive emission monitoring

• Efficiency improvement in existing Wind Mill facility

• Installation of Solar Panels in Townships

• Move towards Alternative source of energy (Bio Gas, Wind Energy)

• Rain water harvesting pits and collecting sumps inside the factor

ENVIRONMENTAL PROJECTSENVIRONMENTAL PROJECTS

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With 3 wind farms (61 Windmills) having a total installed capacity of 15 MW, generated 25346 MWH from 2006 to 09

Solar photovoltaic : 9.3 MWH in 2006-09

Bio gas plant installed with capacity of 100 kg/day of canteen waste normal charging rate is 25-30 kg/day

USE OF RENEWABLE ENERGYUSE OF RENEWABLE ENERGY

Bio Gas Plant Solar Panel Wind Farm

20,000 + tree

saplings planted

In 2009-10

20,000 + tree

saplings planted

In 2009-10

ENVIRONMENTAL EXCELLENCEENVIRONMENTAL EXCELLENCE

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Back wash water was being discharge to natural water pond which has no end use. Now it is being diverted for irrigation to Jatropha plants resulted in annual water savings of 16800 m3

Use of Cooling tower blow down as a make up for fire water

Use of Mix-slop oil as a fuel - equivalent to 9605 MT Natural Gas

Use of Gas Cracker off gas & EPRU flash gas as a fuel – equivalent to 28791 MT Natural Gas

Use of Hydrogen from Chlor Alkali plant as a fuel – equivalent to 4663 MT Natural Gas

Use of cooling tower blowdown for Horticulture resulted in annual water savings of 21900 m3

RESOURCE CONSERVATIONRESOURCE CONSERVATION

ECO POND FOR MIGRATORY BIRDSECO POND FOR MIGRATORY BIRDS

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ECO POND FOR MIGRATORY BIRDSECO POND FOR MIGRATORY BIRDS

EMPLOYEE ASSOCIATIONEMPLOYEE ASSOCIATION

• Seminars and Conferences • In house environment management system-Green card

performance rating system(GPRS)• Encourage and facilitate dialogue and participation to release

full potential of human asset at the site in the area of environment improvement

• Cascading the environmental KPIs to individual manufacturing plant/service plant/ non plant

• Offer the freedom for new environmental initiatives and reward for performance and breakthroughs

• Allocation of funds for Environment management & utilization

Total No of

employees

No. of Training Programmes

No. of Participants Percentage of total

employees trained

SafetyEnvironment

Occupational Health

Management

OfficersWorkmen

3776 61 28 29 275 173 1394 48.78

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IMPLEMENTATION OF IMSIMPLEMENTATION OF IMS

CertificateCertificate ObservationsObservations Action takenAction taken

ISO 9001:2008

Five customer complaints for PVC were received in 09-10. As per recommendation of CTS; actions are identified to implement during shut down activity. However PVC plant persons are not aware of these complaints & planned actions although shutdown is planned from 6th May-10

Plant HOD will segregate all customer complaint in XL sheet. It will be reviewed monthly. Corrective actions required from concern department will be followed up

ISO 14001:2004

At Ethane Propane recovery plant. About

6.5 MT of spent carbon is generated.

1. It is not identified as an environmental aspect

2. Spent carbon after removal from system & kept in open area for further cooling with water. Water is going to storm water and no dyke wall provided to stop spillage on land

1. Aspect-impact register reviewed. 2. New location for storing of spent carbon is identified which is having dyke wall.

OHSAS 18001:2007

At PVC warehouse Waste drum identified for "Cotton Waste", other scarp materials & rubber items found dumped in it.

SOP will be revised for sorting of waste and its storage in the designated area

Some of Corrective/Preventive action taken based on IMS Audit

GOALS

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Not EnvisagedNot EnvisagedComplexVFD scoping study of complex

6

EPRU

EPRU

GCU

GCU

Yard

Plant

10

200

40

150

1.2

InvestmentRs Lacs

109

80

76

100

52

SavingsRs Lacs

LP steam common header scheme for EPRU plant to reduce PRDS load

Installation of hydraulic turbine at amine contactor

Increase in residue gas exchanger area for better heat recovery

Provision of LP ethylene from GCU to VCM to offload C2R and C3R

Provision of Isolation Valve in Yard Piping phase I side

Title

5

Sr. No.

1

2

3

4

Projects Underway 2010Projects Underway 2010--1111

12.552VCMEDC Furnace-I WHB Forced Circulation

10

-Intangible/Improves operator awareness

All plants

DCS Display of Kcal/Kg of product and Kcal/hr for all plants

11

57.6127.2CTCooling water pumps corrocoating

9

1842.0MEGReplacing E 624 which a shell and tube type exchanger with a plate type heat exchanger

8

5.942.85MEG

Replacing E 521 ( Reactor feed pre heater and ensuring one phase flow going to E560 ( aldehyde stripper condensate cooler ) to prevent leaking of its tubes.

7

InvestmentRs Lacs

SavingsRs Lacs

PlantTitleSr. No.

Projects Underway 2010Projects Underway 2010--1111

25

Further Information please contactDipak Mehta – dipak.mehta@ril.com

Paresh Vasava – paresh.vasava@ril.comYusuf Husain – yusuf.husain@ril.com