1
ENERGY CONSERVATION EFFORTS AT RCF
R. P. SHARMA, Dy. General Manager, R.C.F. Ltd.,
Mumbai

• By
• R. P. Sharma, Dy. G.M.
• TECHNICAL SERVICES
• RASHTRIYA CHEMICALS FERTILIZERS LTD. TROMBAY
  UNIT MUMBAI

2
MAJOR ENERGY INPUTS
STEAM
ASSOCIATED GAS
ELECTRICITY
FUEL OIL
3
AVERAGE CONSUMPTION LEVELS AT FULL LOAD
ASSOCIATED GAS 2.0 MMSCM per Day 660 MMSCM per Year
POWER 1000 MWH per Day 3,30,000 MWH per YEAR
4
APPROACH TOWARDS ENERGY CONSERVATION
REPORTING REVIEWING
ENERGY AUDITS
SUGGESTION SCHEMES
5

• METHODOLOGY FOR EVALUATION OF ENERGY CONSERVATION
  SCHEMES

• Is the scheme Techno-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)
Sr. NO PLANT SCHEME ENERGY SAVING POTENTIAL (Estimated)
1 Ammonia I Ammonia I Ammonia I
Cooling Tower pumps B D are replaced with higher capacity pumps. This shall enable plant to run with only 2 CT pumps instead of 3 pumps Cooling Tower pumps B D are replaced with higher capacity pumps. This shall enable plant to run with only 2 CT pumps instead of 3 pumps 1.52 Lakh kwH power saving.
Provision is made to take DM Water directly to Ammonia-1 plant Deaerator from Ammonia-V Provision is made to take DM Water directly to Ammonia-1 plant Deaerator from Ammonia-V 0.88 Lakh kwH power saving
2 Methanol Methylamine plant Methanol Methylamine plant Methanol Methylamine plant
11 kW Slope water (P3) pump is kept stopped and slope water is pumped directly form PP-103 Pump to LP Deaerator 11 kW Slope water (P3) pump is kept stopped and slope water is pumped directly form PP-103 Pump to LP Deaerator 0.87 Lakh kwH power saving
Instrument Air Compressor (CPT compressor) is kept stopped and Instrument Air is being taken from Factory IA grid Instrument Air Compressor (CPT compressor) is kept stopped and Instrument Air is being taken from Factory IA grid 5.50 Lakh kwH power saving
11
CONTINUED
Sr. NO PLANT SCHEME ENERGY SAVING POTENTIAL (Estimated)
1 Ammonia V Ammonia V Ammonia V
Corro - coating of six cooling tower pumps has been carried out. This has increased throughput of pumps and hence enabled stoppage of one pump. Corro - coating of six cooling tower pumps has been carried out. This has increased throughput of pumps and hence enabled stoppage of one pump. 42.06 Lakh kwH power saving.
Energy efficient coating of refractory in primary reformer resulted in reduction of Reformer fuel consumption by 1. Energy efficient coating of refractory in primary reformer resulted in reduction of Reformer fuel consumption by 1. 6.20 Lakh Nm3 Fuel saving
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