ROHM AND HAAS (INDIA) PRIVATE LIMITED TALOJA UNIT

59

First Prize

Chemicals

ROHM AND HAAS (INDIA) PRIVATE LIMITED

TALOJA UNIT

Raigad, Taloja (Maharashtra)

Unit Profile

Rohm And Haas Company was established in 1907 in Esslingen to manufacture &

sell technologically superior and unique chemical product for leather industries.

Rohm And Haas Company develops specialty & performance materials for

customers; products are sold around the world & used in many industrial and

consumer product applications worldwide including Building & Construction,

Electronics, Food & Retails, Household & Personal care, Industrial Process,

Packaging and Transportation & Water.

Rohm And Haas Company started operations in India in 1995 through its subsidiary

Rohm And Haas (India) Private Limited and thereafter established its manufacturing

unit at Taloja, India in August 2003 to manufacture Water Based Latex Polymer -

(DCM- Dow Coating Material) and Polyester & Polyurethane - (Advance Functional

Material). This plant is on 70,000 m2 plot having most advanced automation &

process control design.

The Taloja Plant is IMS certified company for ISO-9001:2008, ISO-14001:2004,

ISO-18001:2007 & Responsible Care.

Energy Consumption

Taloja Plant considers energy saving as a multi disciplinary approach. The energy

conservation projects have resulted in both tangible and intangible savings.

2013 Energy Conservation Program

Savings 149.06 Lakh

Investment 66.05 Lakh

EC Projects 12 Nos.

Specific Energy Consumption Reduction Achievements

With implementation of all energy conservation measures in 2013 both Electrical &

Thermal energy consumption reduced in 2013 compared to 2012 as evident in

below matrix & graphs.

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Description Unit 2012 2013

Total Electrical Energy Consumption Lakh kWh 56.43 53.60

Total Thermal (F. Oil) Energy

Consumption

KL 1153.47 1006.42

Total Thermal (LPG) Energy

Consumption

Lakh m3 1.45 1.31

Total Electrical Energy Consumption MTOE 481.40 459.37

Total Thermal energy consumption in

MTOE (FO+LPG)

MTOE 1290.34 1131.29

Total Production (Water Based Latex

Polymer + Polyester & Polyurethane)

MT 61443.56 66387.50

Specific Electrical Energy Consumption kWh/Tonne 91.83 80.73

Specific Electrical Energy Consumption million

kCal/ tonne

0.21 0.18

% Reduction in SEC Electrical over

2012

% - 12.08%

% Reduction in SEC Thermal over

2012

% - 12.33%

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Energy Conservation Measures Taken

Hot DI Water Heating System Optimization

HOT DI Tank With VPRV &

U-Loop

Installed VPRV, dip pipe to water circulation line & U-

loop to hot water tank overflow line to eliminate vapor

losses. With this change and small automation for Hot

DI water heating configuration in DCS eliminated

energy losses, which resulted in huge Furnace oil

savings.

First Year saving : Rs. 12.20 Lakh

Thermal Energy Savings : 27.02 KL/Annum

Investment : Rs. 4.50 Lakh

Hot oil Heater System Optimization

Hot Oil Heaters

Optimizing hot oil system operating parameters for

loading/unloading of hot oil unit, circulation line/vessels

insulation change and lean productivity approach with

better production planning & co-ordination helped

reduce idle losses & consistent supply of > 265 °C to

process resulting in batch time cycle gain and huge

saving of Furnace oil.

First Year saving : Rs 53.47 Lakh

Thermal Energy Savings : 118.43 KL/Annum


Cold DI Circulation Pump Automation

New HE CDI Pump with 5.5

kW Motor

Installed additional 5.5KW rated cold DI water

circulation pumps apart from 22KW existing pumps and

configured in DCS with operator interface enabling

them to operate bigger pumps during batch process

that are required for 3-4 hrs/day and smaller pumps

rest of the time thus reducing idle energy losses.


Electrical Energy Savings : 100100 kWh/Annum


Hot DI Circulation Pump Automation

New HE HDI Pump with

5.5 kW Motor

Installed additional 5.5KW rated hot DI water

circulation pumps apart from 22KW existing pumps and

configured in DCS with operator interface enabling them

to operate bigger pumps during batch process that are

required for 2-3 hrs/day and smaller pumps rest of the

time thus reducing idle energy losses




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MDI Oven Drum Toughing Time Cycle Reduction

MDI Drum Oven With VFD

Modified the MDI oven hot air circulation ducts and

lower fills, reduced the drum roller conveyor speed by

installing the VFD, re distributed/ layout of the

electrical heater system coils including more energy &

efficient copper electrical heater coils reduced MDI

drum toughing time cycle from 14 hrs to 4-5 Hrs.




Bester Oven Drum Toughing Time Cycle Reduction

Bester Oven With TIC

Controller

Modified the bester oven hot air circulation ducts and

lower fills, modified the steam supply and its steam

condensate return lines, replaced TD type steam traps

with efficient TD Float type steam traps, replaced &

fine tuned the TIC & Steam supply set point/logic etc

reduced drum toughing time cycle from 16 to 6-7

Hrs.



Thermal Energy Saving : 21.0 KL/Annum


Decanter Oven Drum Toughing Time Cycle Reduction

Decanter Oven With TIC

Controller

Modified the Decanter oven hot air circulation ducts

and lower fills, modified the steam supply and its

steam condensate return lines, replaced TD type

steam traps with efficient TD Float type steam traps,

replaced & fine tuned the TIC & Steam supply set

point/logic etc reduced drum toughing time cycle from

16 to 6-7 Hrs



Thermal Energy Saving : 21.0 KL/Annum


T1 Cooling Water Circulation pump Replacement with HE Pump

New 300M3/Hrs, 75KW CT

Pump

Installation & Operation of single 300M3/hrs, 45M

head, 75KW cooling water pump instead of operating

2 nos, 250M3/Hrs pumps to meet production plant &

utilities cooling water requirement resulted in energy

savings of 9000-10000 kWh/Month




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Plant HVAC optimization

New 1.0 TR 5-Star Split AC

Replaced Administration & laboratory buildings old 7.5

to 15TR Central A/C system with 1.0 TR 5-Star rated

energy efficient split A/C for individual cabins.




Air Compressor loading/unloading Optimization

Air Compressor With VFD

Air compressors loading/unloading set points have

been optimized to enable air compressor with VFD

operate maximum time and second compressor comes

online only in case the air pressure drops below 5.5

bar.




Reduction in RTO Offline energy losses

RTO Unit

Reduced Re-Therm Thermal Oxidizers offline energy

losses due to trips caused by power fluctuation & high

LEL in VOC by installing UPS to back its control panel

& modified LEL sensor installation and air dilution after

discussion with OEM.



Thermal Energy Saving : 13918 m3 LPG/Annum


HOU pump replacement with HE pumps

New HE HOU Mag. Drive

Pump

Replaced all 4 nos. 15 kW rated centrifugal pumps

with 7.5 kW rated Nikkiso Make canned Motor pump

having EFF1 rated motors used for circulation of

thermic fluid for process heating.




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Second Prize

Chemicals

IOL CHEMICALS AND PHARMACEUTICALS LIMITED

Barnala (Punjab)

Unit Profile

IOL Chemicals and Pharmaceuticals Limited (IOLCP) is a chemicals and API’s

manufacturing industry, located in Barnala (Punjab). The company was started with

a small project of Rs. 65 million to manufacture 4500 TPA of Acetic Acid and has

now diversified into a multi product company to manufacture the Chemicals and

API’s Like 87000 TPA Ethyl Acetate, 30000 TPA Acetic Anhydride, 5200 TPA Acetyl

Chloride, 7200 TPA Mono Chloro Acetic Acid, 9000 TPA Iso Butyl Benzene and 6000

TPA Ibuprofen. At present company’s annual sales is more than USD 100 million

with export to more than 50 countries

Energy Consumption (Chemical Division)

IOLCP has identified various Energy conservation projects, which has resulted in

Energy saving and contribution to the nation in preservation of precious resources of

Energy. Last two years energy consumption figures are shown below.

Description Unit 2012-2013 2013-2014

Electrical energy consumption million kWh 5.3 4.2

Thermal energy consumption million kCal 46198 43131

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Specific Energy Consumption for Chemical Plants (Chemical Division)

• Specific Electrical Energy Consumption


Acetyl Chloride kWh/MT 360 199

Mono Chloro Acetic Acid kWh/MT 291 228

Iso Butyl Benzene kWh/MT 630 570

• Specific Thermal Energy Consumption


Acetyl Chloride M kCal/MT 3.3 3

Mono Chloro Acetic Acid M kCal/MT 4.1 3.8

Iso Butyl Benzene M kCal/MT 3.4 3.1

Energy Conservation Projects Implemented During 2013-2014

1. Installation of the dopp kettle to recover solvent in Iso propyl chloro

acetate plant(IPCA)

Spent acid, which is discharged from IPCA plant to

Effluent treatment plant(ETP), contains traces of

solvents i.e. Isopropanol and Isopropyl chloro

acetate. In order to recover these solvents, dopp

kettle is installed in the process, in which under

vacuum distillation of spent acid is done before the

discharge of spent acid to the ETP. The unit is,

now, recovering the traces of solventalong with

less power consumption in the ETP.

Electrical Energy saving : 0.2 million kWh/Annum

Total in saving : Rs. 1.4 millions

Payback period : 0.5 year

2. Optimization of consumption and ratio of Potassium carbonate and

Sodium metal catalyst in Iso butyl benzene (IBB) plant.

In old system, Potassium carbonate and Sodium

metal consumption in Iso butyl benzene (IBB) plant

is at a ratio of 10:1 and consumption was 500 kg

per batch. At this condition rotary vacuum dryer

was able to dried Potassium carbonate for a single

batch only. On the basis of R&D trials, the Unit has

reduced the Potassium Carbonate to Sodium metal

ratio from 10:1 to 6:1 and consumption from 500

kg per batch to 300 kg per batch. After reducing

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the consumption of Potassium Carbonate, the Units is now able to dry potassium

carbonate in Rotary vacuum dryer for two batches in a single batch time by

utilize full capacity of dryer.


Total in saving : 2.8 million


3. Re-Engineering of process parameter to increase the recovery of

Potassium carbonate in Iso butyl benzene (IBB) plant.

In old process, recovery of potassium carbonate

was done in the crystallizers at normal pressure.

With the help of simulation software, the Unit

analysed operating conditions, i.e. in between

normal pressure v/s under vacuum to improve the

recovery of potassium carbonate and generated

the data. Result of analysis shows that the

recovery of potassium carbonate gets increased

with reducing the operating pressure of crystallizer. With the help of R&D data,

the Unit implemented the revised operating parameters into the plant. Now, by

applying vacuum in the crystallizer the quantity of mother liquor gets reduces

which ultimately increase the recovery of potassium carbonate. Hence the yield

of potassium carbonate increases.


Steam saving : 2000 MT/Annum



4. Optimization of Mono Chloro Acetic Acid (MCA) Plant process parameter

to reduce the steam and power load on Utility

On the basis of in house R&D center for

optimization of the operating parameters of Acetyl

chloride column and chlorinator reactor, pressure of

chlorinator reactor was reduced from 3.5 kg/cm2 to

2 kg/cm2 and Acetyl chloride column pressure

reduced from 0.8 kg/cm2 to 0.25 kg/cm2 which

ultimately reduced the consumption of steam and

also reducing the load on utility in the system. By

reducing the pressure of steam and improving the efficiency of reboiler of acetyl

chloride distillation column.


Steam Saving : 1000 MT/Annum



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5. Isolate the one stage of steam jet ejector by installation of Flash Tank.

In Monochloro Acetic Acid (MCA) plant, MCA

distillation column operates under vacuum. The

vacuum is generated with the help of three steam

jet ejectors. In the modified system, the Unit

installed a flash tank in the fresh feed to the

distillation column so that all the non-condensable

gases can be separated out and send to the three

stage acetyl chloride reactors and which will reduce

the load on steam jet ejectors. By reducing the load, one stage of the steam jet

ejector was reduced resulting in save the steam and CT water consumption.




6. Using flash steam of condensate tank in acetyl column feed

Flash Steam Generated from the steam condensate

is being used in the acetyl distillation column of

MCA plant. By the use of flash steam, thermal

energy is saved.




Energy Conservation Commitment

Energy conservation continuous to be an area of major emphasis for IOL chemicals

& pharmaceuticals limited. Unit has been continuously putting efforts to reduce

specific energy consumption by both improving the technology and energy

efficiencies.

Documents

ROHM AND HAAS (INDIA) PRIVATE LIMITED TALOJA UNIT