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KOTHARI PETROCHEMICALS LTD
MANALI- CHENNAI
CII- 22nd NATIONAL AWARD EXCELLENCE IN ENERGY MANAGEMENT 2021
TEAM MEMBERS:Mr. Anand B R – Sr. Manager- TLSMr. Saravanan J- Energy managerMr. Karunamoorthy R- Asst. Manager- TLS
1. KPL Business overview
Sugar Petro Chemical
DepositLocker
Bio Tech
Power Distillery
19901936 19611961 19611961
KPL is a part of the renowned “HC Kothari Group”, we are the largest producer of premium quality Polybutene in India. Since our founding in 1990
KPL OUTLINE
PlantCommissioned
March 1990
Technology of the
ProcessCOSDEN
Earlier Plant Design
Capacity5000 MTA
In the Year Of 2002Capacity
Increased to 8400 MTA
In the Year Of 2007
PIB Train-2 was commissioned
Capacity Enhanced to
24KTAYear of
2007 - 2008
State of Art 2MW CPP PlantCommissioned
Year of 2018
Safety & Engineering Park
Created Year of 2020 Highest
Production of 25KTA was
achieved in the year of FY20-21
Capacity Enhanced to
36KTAYear of
2020 - 2021
C4 Raffinate Storage
Reactor section
Neutralization section
De Butanizersection
Flashsection
Polymer storagesection
LP Storagesection
Blendingsection
FFU /Feed Treatsection
FS-2CPCL
FS-1CPCL
FS-3OTHER
RETURNCPCL
RETURNCPCL
C4 RAFFINATE TO SPHERE
C4 RAFFINATE TO REACTOR
FEEDSTOCK-2iB CONC- 8-12%
FEEDSTOCK-1iB CONC- 18-22%
FEEDSTOCK-3iB CONC- 99.9%
ENRICHEDiB CONC- 18-22%
CATALYSTSLURRY
10-15% NaOH
SPENTNaOH
OTHER BUTANES/ UNREACT
WEAK CAUSTIC
SOLN
CAT+POLYMER
4-6%
SPENTCAUSTIC
SOLN
OTHER BUTANES/ UNREACT
POLYMER+LP+
UNREACT +CATALYST
POLYMER+LP+
UNREACT
POLYMER+LPPOLYMER
*iB- isobutylene; LP-Light Polymer; CPCL-Chennai petroleum corporation limited
LP
2. Manufacturing Process Flow
3. Impact of COVID-19
❖This pandemic has really tipped the balance of Global economy.
❖COVID 19 really taught us more. During the pandemic, we were at the stage we have to run the
plant at lower capacity. In this situation we are very keen on energy consumption.
❖We have a restricted our manpower as per government guidelines.
❖ Our team gave a greater support to run the plant at very efficiently and very productively.
❖We have Increased our productivity by 5%
❖We have Reduced our energy consumption by 5%.
❖We were at the stage, we have to export more than domestic demand. Which has a greater impact
in freight and transportation.
4. Energy Consumption Overview
Plant absolute energy consumption FY-2020-2021
-
500.0
1,000.0
1,500.0
2,000.0
2,500.0
3,000.0
3,500.0
4,000.0
Power, toe Thermal, toe Total Plant, toe
831.6
3,132.2
3,964
FY-21
Power, toe21%
Thermal, toe79%
PLANT TOTAL ENERGY CONSUMPTION
4. Energy Consumption Overview (Last three years)
❖Total power consumption dropped by 4%
❖ Total Thermal energy consumption increased by
13%
❖ Energy consumption increase 9%
❖ Productivity increase 5%
94,00,000
95,00,000
96,00,000
97,00,000
98,00,000
99,00,000
1,00,00,000
1,01,00,000
FY-19 FY-20 FY-21
96,75,421
1,00,73,994
96,72,070
Power consumption, kWh
2,500.0
2,600.0
2,700.0
2,800.0
2,900.0
3,000.0
3,100.0
3,200.0
FY-19 FY-20 FY-21
2,727.5 2,743.3
3,132.2
Thermal energy consumption, toe
3,300
3,400
3,500
3,600
3,700
3,800
3,900
4,000
FY-19 FY-20 FY-21
3,560 3,610
3,964
Total energy consumption, toe (Power+Thermal)
5. Specific Energy Consumption (Last three years)
0.0
100.0
200.0
300.0
400.0
500.0
FY-19 FY-20 FY-21
488.3
421.4386.9
Power Sp. Consumption MT/MT
1000000.0
1050000.0
1100000.0
1150000.0
1200000.0
1250000.0
1300000.0
1350000.0
1400000.0
FY-19 FY-20 FY-21
1377262.1
1148194.9
1253547.7
Thermal energy consumption Kcal/MT
0%
20%
40%
60%
80%
100%
FY-19 FY-20 FY-21
1377262.1 1148194.9 1253547.7
419927 362404 332706
Total Energy Sp. Consumption Kcal/MT (Thermal + Power)
Reduced By 8%
Increased By 9%
Increased By 5%
5. Production Details (Last three years)
0
5000
10000
15000
20000
25000
30000
FY-19 FY-20 FY-21
19815
2390625001
Production, MTAIncreased
By 5%
5. Energy Consumption Plan- FY22&23
Plan to Reduce Energy Consumption:
❖ Increasing Feed throughput & concentration to reactor, increase in productivity with in house trials
❖ Identifying Bottlenecks and implementing process change.
❖ Utilization of plant at maximum capacity, Running the plant without interruption.
❖VFD Provision for Butane compressor to optimize the load and energy consumption.
❖ Implementing waste heat recovery system- Pinch Analysis
❖ Best Engineering practices of- Thermal survey across the plant; Ultrasound leak detection program.
0.0
200000.0
400000.0
600000.0
800000.0
1000000.0
1200000.0
1400000.0
FY-19 FY-20 FY-21 FY-22 FY-23
1377262.1
1148194.91253547.7
1029893.0 1009093.0
Thermal energy consumption Kcal/MT
0
50
100
150
200
250
300
350
400
450
500
FY-19 FY-20 FY-21 FY-22 FY-23
488.3
421.4386.9
362 353
Power Sp. Consumption, kWh/MT
5. Specific Energy Consumption
Factors Influencing SEC variation.
Internal Factors External Factors
Grade change over
Shutdown & Start-up
Employee Participation
De Bottlenecking trials
Effective energy management system
Capacity utilization due to market demand
Climatic condition
Fuel Price/ Availability in Market
OEM/ Customer requirement
Raw material availability & Quality
Preventive maintenance
6. Energy Project Implemented (Last three year’s)
2018-2019
2019-2020
DESCRIPTION ZERO INVESTMENT WITH INVESTMENT TOTAL
Project in No's 1 6 7
Total Investment in Million 1.946
Total savings in Million 7.71
Total Energy saving- Thermal MKcal/Year 4132.2
Total Energy saving- Power MkWh/Year 0.15
Total Water saving- KL/Year 28800
Pay Back in Months 3
DESCRIPTION ZERO INVESTMENT WITH INVESTMENT TOTAL
Project in No's 5 5 10
Total Investment in Million 0.33
Total savings in Million 21.1
Total Energy saving- Thermal MKcal/Year 9711.3
Total Energy saving- Power MkWh/Year 1.34
Total Water saving- KL/Year 6840
Pay Back in Day's 0.2
2020-2021
DESCRIPTION ZERO INVESTMENT WITH INVESTMENT TOTAL
Project in No's 7 9 16
Total Investment in Million 6.22
Total savings in Million 7.53
Total Energy saving- Thermal MKcal/Year 1301
Total Energy saving- Power MkWh/Year 0.66
Total Water saving- KL/Year 25430
Pay Back in Month's 9.9
6. Energy Project Implemented (2020-2021)
Project Implemented : Waste heat recovery from LP condensate drum vent using PHE
Description:❖ LP steam is used in Feed fractionation unit, condensate from FFU is being stored in separate
collection drum and send back to boiler. ❖ Flash steam from the drum kept in local. ❖ New PHE provided to recover the heat from flash steam vent.
Investment made : 0.8 Lakhs
Benefit achieved :❖ Total clean condensate collection- 600KL/Annum❖Total thermal energy saving – 441MKcal/ Annum❖ Total cost savings – 5.7 Lakhs/Annum
Pay Back Period: 1.7 Month
6. Energy Project Implemented (2020-2021)
Project Implemented : Waste Heat recovery from HP condensate drum vent using PHE
Description:❖ HP Condensate drum vent is been connected with condenser lined-up with CT water.❖ New PHE provided and connected with Boiler feed water to pre heat and send to Boiler. ❖ The heat load is been going to cooling tower is been diverted to Boiler feed water.
Investment made : 5.34 Lakhs
Benefit achieved :❖ Total clean condensate collection- 1348KL/Annum❖Total thermal energy saving – 718MKcal/ Annum❖ Total cost savings – 9.08 Lakhs/Annum
Pay Back Period: 27 Days
6. Energy Project Implemented (2020-2021)
Project Implemented : Capacitor provision for MCC-2
Description:❖ During continues monitoring of MCC panel, PF found to be low in MCC-2, ❖ Which has been identified and capacitor was provided to balance the load. Now it is running
normal; Before PF-0.77; After PF-0.95
Investment made : 1.59Lakhs
Benefit achieved :❖ Total thermal energy saving – 0.1MkWh/ Annum❖ Total cost savings – 5.01 Lakhs/Annum
Pay Back Period: 3.8 Months
6. Energy Project Implemented (2020-2021)
Project Implemented : Condensate collection from FG Storage area
Description:❖ FG Tank heating condensate drain into gutter, the clean condensate can be re use to boiler
feed tank.
Investment made : 16.57Lakhs
Benefit achieved :❖ Total water saving – 7200KL/Annum❖Total cost savings – 9.36 Lakhs/Annum
Pay Back Period: 21 Months
6.Energy Project Implemented (2020-2021)
Project Implemented : Pump swaping in Process (High capacity pump to low capacity pump)
Description:❖ Process water injection pump have a high head and high capacity❖ Since we required low capacity (50% of the pump capacity is been utilized). ❖ Pump is been replaced with adequate pump (redundant pump).
Investment made : Zero Investment
Benefit achieved :❖ Total Power saving – 6048/Annum❖Total cost savings – 0.35 Lakhs/Annum
Pay Back Period: -
6. Energy Project Implemented (2020-2021)
Project Implemented : UP-9000 Leak detector usage.
Description:❖ Since we are handling LPG as a raw material we are unable to detect the untraceable (Lower
than detection level) quantity of LPG leak. ❖ Now we have procured ultra sound leak detector to identify the Fugitive emission from
process.
Investment made : 5.0 Lakh
Benefit achieved :❖Total cost savings – 1.16 Lakhs/Annum
Pay Back Period: 4 Months
7. Innovative Project Implemented
Project Implemented : RO Reject water using for cooling tower
Description:❖ RO Reject water is been used for cooling tower makeup. ❖ Earlier we use metro water to produce DM water. ❖ Since the conductivity of metro water is high it is necessary to treat RO reject water in our
Effluent treatment plant. ❖ Now we signed MOU with CMWB to use TTRO water from their STP unit. ❖ This water quality is better than metro water, conductivity and other parameters are match
the CT makeup water.
Investment made : 29.8Lakhs
Benefit achieved :❖ Total water saving – 7279KL/Annum❖ Total thermal energy saving – 0.21MkWh/ Annum❖ Total cost savings – 17.98 Lakhs/Annum
Pay Back Period: 20 Months
7. Innovative Project Implemented
Project Implemented : Hot condensate using for wash vessel makeup instead of cooled condensate
Description:❖ Earlier cold condensate from Ejector is being used for wash vessel.❖ Hot condensate from common condensate collection drum is being cooled and used for column
injection. ❖ Injecting the cool condensate to wash vessel incur heat loss and also lead to washing inefficiency, hot
condensate from common condensate collection drum can be directly use into wash vessel, at the same cool condensate from ejector directly use for column injection without additional cooling.
❖ By doing this heat load to cooling tower is reduced, the equivalent amount of heat load is being used for washing section pre heater has been reduced, and also cooled condensate injection pump to column has be isolated.
Investment made : Zero Investment
Benefit achieved :❖Annual water saving – 242 KL❖ Annual thermal energy savings – 142.3 Mkcal❖ Total cost savings – 2.02 Lakh
Pay back Period: -
8. Utilization of renewable energy source
Onsite Solar farm-2
93.6kWh
OnsiteSolar Farm- 1
156kWh
We have Bio- Mass Operated Captive
Power Plant2MW
Installed in KPL Site
8. Utilization of renewable energy source (Last three years)
7.5%
90.1%
2.5%
Power source FY19
EB/DG
Biomass
Solar
2.3%
95.4%
2.3%
Power source FY20
EB/DG
Biomass
Solar
❖We produce and consume around 92% of our
own power requirement through renewable energy
resource (Solar + Bio mass)
7%
90%
2% 1%
Power source FY-21
EB/DG
Biomass
Solar
Coal
9. Utilization of waste material as fuel
Waste Utilization:❖ OFF Gas recovery system was implemented, recovered and reused for TFH System.❖ Earlier TFH system was run by FO.❖ OFF Gas recovery and utilization was gradually increased in 56% Plan FY22:❖ Implementation of complete OFF gas recovery system inclusive of pump drain, coalescer drain..etc.
0
100
200
300
400
500
600
700
800
900
FY-19 FY-20 FY-21
388.8
624.6
890.5
OFF Gas recovery MTA
0.0
100.0
200.0
300.0
400.0
500.0
600.0
700.0
800.0
900.0
1000.0
FY-19 FY-20 FY-21
413.8
664.8
947.7
Energy Recovery toe/Annum Increased By 56%
Green Go Project
Project Implemented : HPIB Purchase
Description:
❖ Earlier procurement concentration of C4 raffinate is 33%
❖ Now the procurement concentration of C4 raffinate is 99%
❖ Number of round trip got reduced- 1700 No’s
Investment made : Zero Investment
Benefit achieved :
❖ CO2 emission reduction- 6551.5 MT/Year
10. GHG Emission Intensity and Verification (Last Three Years)
❖ Total GHG intensity reduction is 2.5%
0.000
0.100
0.200
0.300
0.400
0.500
0.600
0.700
FY-19 FY-20 FY-21
0.645
0.568
0.415
Power- CO2 Emission MT/MT
0.000
0.050
0.100
0.150
0.200
0.250
0.300
0.350
0.400
0.450
FY-19 FY-20 FY-21
0.379
0.319
0.450
Thermal CO2 Emission MT/MT
0.750
0.800
0.850
0.900
0.950
1.000
1.050
FY-19 FY-20 FY-21
1.024
0.8870.865
Total CO2 Emission (Thermal + Power) MT/MT
Reduced By 26%
Increased By 29%
Reduced By 2.5%
10. GHG Emission Intensity Reduction Plan
CO2 Emission Reduction MT/MT
Short term goals:❖ Implementing complete OFF Gas recovery system❖ Conducting Insulation efficiency survey❖ Increasing the Productivity with in House trials.❖ Increasing waste heat recovery across the plant.
Long term goals:❖ Converting Fuel Bio Mass to Clean Fuel (LNG)❖Conducting comprehensive energy audit (3rd Party)❖ Increasing the productivity with the help of De Bottleneck.
0.000
0.200
0.400
0.600
0.800
1.000
1.200
FY-19 FY-20 FY-21 FY-22 FY-23
0.645 0.5680.415 0.380 0.350
0.379
0.3190.450
0.3950.365
CO2 Emission reduction MT/MT
CO2-Power Sp.Consumption CO2 Emission- Thermal
Reduction By 18%
10. Fly Ash Utilisation
❖ Bio Mass Operated boiler Fly Ash Disposed to Fly ash Brick Manufacturers
Disposal : 100% Daily generation of Fly ash disposed to Fly ash Manufacturer.
❖ Mode of Disposal: Closed Container.
❖ Environmental Benefit: 100% recycle to eco friendly Brick making
12. KPL Energy Cell
Top Management
Energy Manager
Administrative Department
Technical Service Department
Finance Department
Energy management committee
Production In-charge
Plant Maintenance
12. Energy Team Work- National Energy Conservation Day Celebration
ENERGY BEST SUGGESTION: Mr. PANDIYANCOALESCER INSULATION PROVISION TO AVOID HEAT RADIATION
ENERGY BEST SUGGESTION: Mr. ARUL MURUGANPUSH TYPE TAP FOR DRINKING WATER TO AVOID WATER LOSS
“7QC Tools”3 Day’s External workshop conducted Cost Impact of Leak
Energy Training- Importance of energy conservation in industriesBest Engineering Practices- “Using Ultra Sound”
Description Value
Total Number of training provided- In House Training
05
Total Number of training provided- By ExternalTraining
02
Total number of training participants 52
Total number of man hour training completed 98
12. Energy Team Work
Energy Cell Activity
Energy Training and Development
Leak Identification program
Description Value
Total steam leak identified across ISBL 17
Total steam leak arrested - Completed 16
Number of steam leak required Shutdown 01
Cost saving in Steam leak arresting (Rs/Day) 3314
12. Energy Team Work- “GREEN GO” Cycling event Organized
13. Implementation of ISO 50001
❖KPL Have Combination of ISO 9001, 14001,
45001 as IMS in Place.
❖We are way forward to implement ISO 50001:
2018 By End of FY-23; Measures are in place to
convince management.
0.00%
0.05%
0.10%
0.15%
0.20%
0.25%
0.30%
FY-19 FY-20 FY-21
0.06%
0.01%
0.27%
Inve
stm
en
t %
Turnover vs. Enery Project Investment %
Increased By 17%
13. Learning From CII Energy Award 2020
❖ Through CII- Energy award-2020 we have learned some of best engineering practices, are implemented in our site
and got positive result of energy saving; Some of
Ultrasound leak detection survey :❖ Instrument air leak reduction❖Nitrogen leak reduction.❖Fugitive emission reduction (Hydrocarbon leak from process)❖Steam trap testing.
Thermal and Insulation survey :❖ Thermal and Insulation survey instrument procured and schedule has been followed.
Thank you
CONTACT DETAILS:Mr. Anand B R – Sr. Manager- TLSMain ID: [email protected]. No: +91 7299044611
CONTACT DETAILS:Mr. Srinivasan K S – AGM Maintenance / Energy CellMain ID: [email protected]. No: +91 7299044605
