Unichem Lab 2

8/6/2019 Unichem Lab 2

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Energy Conservation Study At UNICHEM LAB, GHAZIABAD

Forbes Marshall Pvt Ltd Pune__________________________________________ 1

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ENERGY CONSERVATION STUDY REPORT

(BOILER HOUSE & STEAM SYSTEM)

AT

UNICHEM LABORATORIES LTD.

LOCATION:

C-31 & 32, INDUSTRIAL AREAMEERUT ROAD

GHAZIABAD-201003(U.P)

PERSONS CONTACTED:MR. D.B.RAY

(MANAGER- ENGINEERING)

STUDY DONE BY :DEBENDU NAG(FORBES MARSHALL)

SUBMITTED BY :FORBES MARSHALL (P) LIMITED,

PB NO. 29, PUNE - MUMBAI ROAD,KASARWADI,

PUNE 411 034.

TEL. 0091-20-39858555FAX 0091-20-27147379

Email: [email protected]


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REF : DLI/DN/UCLL/1407DATE:- JULY 14TH, 2011

UNICHEM LABORATORIES LTD.

C-31&32, INDUSTRIAL AREAMEERUT ROADGHAZIABAD

KIND ATTN: Mr.D.B.RAY (MANAGER- ENGINEERING)

Dear Sir,

Subject: ASSURED SAVINGS OF 19 LAKHS!!!! AND RECOVERY OF VALUABLE CONDENSATE

We sincerely thank you for the kind courtesy extended to Mr. Debendu Nag while he visitedyour plant on 2 0TH JUNE 11 for Energy Conservation from Steam Generation and had the subsequentdiscussion on the subject matter in details.

Energy conservation today is no longer an option with the increasing scarcity of natural resourcesand spiralling costs of energy, energy conservation today is an absolute necessity to sustain anybusiness.

YOU CAN SAVE A TOTAL OF RS. 19 LACS / ANNUM WITH JMN BOILER AND SPIRAX INSTALLATION,WITH A PAYBACK PERIOD OF ABOUT 20 MONTHS

Your present annual fuel bill is- Rs. 91 (Rs. lakhs)Savings Expected: Rs. 19- (Rs. Lakhs ).

We at the Forbes Marshall Group are committed to the cause of Energy conservation and theassociation of Spirax Marshall with the various engineering industries is more than 60 years old.Spirax Marshall has technical and financial partnership with Spirax Sarco Limited, U.K. and is theFlagship Company of the Forbes Marshall group.

If at any moment of time you have any doubt, please feel free to ask.

Thanking you,For Spirax Marshall Pvt. Ltd.Debendu Nag

Forbes MarshallDelhi Steam Engineering [email protected]


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EXECUTIVE SUMMARY

We thank you for the confidence placed in us for suggesting measures of steam and fuel efficiencyimprovement at your plant. There is a significant scope for improvement both tangible and intangible,

tangible being reduction in fuel bill, improvement in productivity and intangibles like reduction of downtime, maintenance costs etc.

The areas of study were,y Boiler housey Steam distributiony Steam Utilisationy Condensate Recovery

This study report finds tremendous savings potential of 19 L that exists at your plant

The major factors influencing the savings are:

1. Steam generation methodology: The existing Coil type boiler is generating very poor quality of steam. Also they are unable to cater to the fluctuating steam demand of the company. If the same arereplaced by Shell type Fire tube boiler, the plant steam demand would drastically come down due toimproved steam quality.

2. Steam Distribution: Avoiding leakages at valves, propers sizing of steam lines, proper selection andinstallation of pressure reducing stations at proper location plays important role in saving steamquantity.

3. Steam Utilisation: Analyse the process problems, such as steam starvation, long batch timing, in-efficient heating. To give suggestion to improve current steam system to ensure hassle freeproduction.

4. Condensate Recovery: Condensate is recovered from the plant and fed into the Feed water tank.But when the temperature of the Feed Water rises above 60Deg C, the condensate is drained. This is awaste of condensate as well as the energy contained in the steam.

We would be pleased to discuss these findings with you and work with you for implementation of thesame and towards achieving the projected savings.


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DETAILED REPORT

With reference to the visit to your plant, the following observations were made of your steamsystem:-

1) Boiler:- The existing boilers at your plant are Coil type boilers of the capacity of 850Kg/hr(2nos). Of them both are required to be run when the plant is on full load condition.

Recommendation:- It is recommended to replace the Coil type boilers by Shell type boilers. In shelltype boilers, the steam produced is 98.5% dry. Also steam starvation is avoided as no water is wastedas hot water.

2) Boiler blowdown: - blowdown is done a t breaks as routine practice.

3) Feed water tank: - the feed water tank is of 5000 Litres, in which 4000 Litres level ismaintained. The temperature of Feed water fed in the boiler is maintained at 60 Deg C. Thechief reason is that the boiler chamber is hot. If water at 90 Deg C Celsius, is passed througheconomiser which raises the temperature to 100 Deg C, it would form steam in the coil itself,thereby rupturing the coils of the boiler. Subsequently, more amount of fuel is required toheat the water from 60Deg C to 150Deg C. This results in increase in the fuel bill.

4) Level Controllers on Feed Water tank: - level controller is installed on the feed water tank.Level controllers are used in Feed water tanks to measure the amount of water present in thetank. There must a minimum level of water in the feed water tank to prevent the boilers fromrunning dry.

5) Steam Flow Meter:- The Steam Flow Meter is present to accurately measure the amount of steam flow. The steam flow meter is a vortex type flow meter which accurately senses andshows the flow of steam. The steam pressure rarely remains constant. With varying pressurethe mass flow rate also varies proportionately. Hence the vortex steam meter that youprocure should have on-line density compensation to give you accurate readings.

BOILER HOUSE


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3) De- Areator Head: - There is d e-aerator head present at your feed water tank. If the makeup

water and flashing condensate are fed to the tank above the water surface, flash steam withall its heat is lost to atmosphere. This results in feed water temperature colder than expected.

The De-aerator head combined with Spirax steam injection system ensures quite but vigorousmixing of steam and feed water to reduce dissolved oxygen content to approx 2ppm. Thisaction reduces the need for oxygen scavenging chemicals. The temperature of the feed wateris maintained at a high steady level for smooth boiler operation.

Fuel consumption and production records:

Average Fuel Consumption per day per boiler(on full load condition) = 350 lts

Average fuel consumption per day(both boilers) = 700 lts

Price of fuel/litre = Rs. 37.5

Number of working days = 312days

Annual Fuel Bill = 700 x 37.5 x 312= Rs. 81,90,000


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BOILER HOUSE

1.1 Study Boiler house (details and findings)Sr.

No.

Description Boiler No. 1 Boiler No. 2 Boiler No. 3

Boiler Data B-1 B-2 B-31 Make Revomax plus Revomax plus2 Year of Installation 2007 20073 Capacity, (Kg/hr) 850 8504 Design Pressure, (Kg/cm 2(g) 10.34 10.345 OperatingPressure,(Kg/cm 2(g) 8 86 Fuel used HSD7 Stack temperature 250Deg C 250Deg C8 O2 % in stack9 CO2% in stack10 Boiler efficiency(NCV) (Rated) 80 % 80%11 Feed Water Temperature( C) 60 Deg C12 Average dryness fraction 65% (Average from Running Pattern)13 Average steam load &

Timings in a daySteam load is nearly constant

14 Seasoned steam demandton/day

Plant running is not seasonal

15 Price of Fuel. (Rs. / Liter) Rs.37.5016 Fuel liters/day average 700 lts of HSD per day17 Annual Fuel Bill Lacs Rs. 82 lakhs18 Working days in a month 26 days19 Feed Water quality/hardness

ppmSoft water/


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Total Steam Load = 1200 kg/hr

Considering a Diversity Factor of 70% = 840 kg/hr

Net Steam Load = 840kg/hr

Considered the future expansion in the pipeline, we would be recommending to go for 2 TPH boiler , F& A at 100 Deg.C.

Fuel Consumption By NIBR(Coil Type ) Boiler

Operating Parameters1. Fuel HSD2. NCV of Fuel 10500 Kcal/kg3. Specific Gravity Of HSD 0.82

4. Efficiency of Boilers(rated) 80%5. Generating Pr. Of Boilers 8bar g6. Enthalpy of Steam at 8barg 661.9Kcal/kg7. Temperature of water at 8barg 176 Deg C8. Temperature of Feed Water 40 Deg C9. Dryness Fraction 65%

For generating a dry steam load of 840 kg/hr, the coil type boilers will, at 65% dryness fraction,generate steam

=840/ 0.65

= 1292 kg/hr

Amount of Steam = 840 kg

Amount of Hot Water = 1292 kg/hr 840kg/hr= 452 kg

Fuel Consumption for generating a 1292kg/hr of steam

= 840(661.9-60) + 452(176-60) / 10500 x 0.8 x 0.82

= (505596 + 52432) / 6888

=81 lts/hr

HSD consumption per day = 81x 10hrs = 810 lts

Price of HSD = rs. 37.5/ lt


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Running Cost of NIBR boilers = 810 x 37.5 x 312 = Rs. 95 lacs

Proposed Feed water Tank Heat Balance

Capacity of the feed water tank = 3000 lts

Level in the tank = 2500lts

Steam Load : 1200kg/hr

Considering 90% of the condensate is recovered,

Amount of recoverable condensate = 1200 x 0.9

= 1080kg/hr

Flash steam = (hf at 5 bar hf at 0.5 bar)/ hfg at o.5= (159 110)/ 532.5= 10%

Flash quantity @10% of condensate load (1080kg/hr) at 0.5 Bar = 108 kg/hr

Resultant feed water temperature, considering all the condensate is used as feed water and the flash

steam is vented at the feed water tank- Incase of Shell boiler, all the energy from Flash andcondensate is recovered and reused in the boiler.

= (972 x 90) + (108 x 610 ) + ( 1300 x 30 )2500

= (87480+ 65880 + 39000) / 2500

= 77Deg C


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Fuel Consumption Of IBR (Shell Type) Boilers

Operating Parameters1. Fuel HSD2. NCV of Fuel 10500 Kcal3. Specific Gravity Of HSD 0.824. Efficiency of Boilers(rated) 89%5. Generating Pr. Of Boilers 10 bar g6. Enthalpy of Steam at 10 barg 662.9Kcal/kg7. Temperature of water at 10 barg 181 Deg C8. Temperature of Feed Water 77 Deg C9. Dryness Fraction 77 %

Steam Load = 840kg/hr

Fuel Consumed to generate 1200 kg/hr of steam

=840 (662.9 77) / 10500 x 0.82 x 0.89

= 65 /hr

HSD consumption per day = 65 x 10 hrs= 650 lts/day

Price of HSD = Rs. 37.5

Running cost of IBR boilers =650 x 37.5 x 312 = Rs.76 lacs


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Savings and Pay Back Matrix

Parameter CASE 1 CASE 2System IBR BOILER NIBR BOILERS

Fuel HSD HSDCost of fuel Rs/Kg 37.5 37.5Operating hours/Day 10 10

Operating days/Year 312 312

Hourly fuel consumption 65 81

Hourly Operating cost 2,437.5 3,037.5Daily operating cost 24,375 30,375Yearly operating cost 76,05,000 94,77,000

Annual Savings from Conversion18,72,000

Savings Percentage 19%

STILL WOULD YOU LIKE TO RUN COIL TYPE BOILERS ???


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COMPARISION

Comparison of IBR Shell Boiler & Non-IBR Coil Boiler Parameter Non-IBR Coil Boiler IBR Boiler

Design O nce through water tube typeboiler

3- pass wet back smoke tubeboiler

Ov erall S team : FuelEff iciency

Low, typically 75% as f oundby actual trials

A s high as 89% on N CV

S team space N one S team space a v ailable to cater to load f luctuations

Pressure control Poor Can deli v er steam at close toconstant pressure

Water holding capacity L imited, typically 22. 5 Kg per coil

Large e .g . , 75 0 Kg/hr J NM IBR boiler holds 1 342 Kg o f water atnormal water le v el

S team release v elocity High,R esulting in poor drynessf raction, typically between0 .65 & 0.75

Low,S team quality is una ff ected byload v ariation, because o f lowsteam release v elocity

Dryness f raction 0 .98

S usceptibility to poor water Water tube design requiresstrict water quality treatment

S moke tube design can do withmedium treatment

S usceptibility to scaling Coils get scaled on the insideand are prone to f ailure

S moke tube design, inner sur f ace o f tubes can be cleanedeasily

M aintenance Ex penses R ecurring cost o f replacing thecoils f requently

Periodic tube cleaning issu ff icient

O n - line B lowdown to maintainT DS

N ot possible A dequate water holding capacityenables on - line blowdown &hence T DS control

B uild Quality o f manu f acture N o standards, no stageinspection duringmanu f acture, poor testing

S tage wise inspection at eachstage o f manu f acture ande x hausti v e testing ensures buildstandard


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SUCCESS STORIESCOIL VS SHELL: PERFORMANCE AND SAVINGS

Customer : BAL PHARMA

B al Pharma has a f ormulation plant at S hirwal, Pune that produces ear/eye drops and I.V. saline . T he plant has a capacity o f producing 5 0,000 bottles (100 ml & 5 00 ml) and 2 0,000 bottles o f I.V. saline

STEAM USING E QUI P MENT

A utocla ve 2 no . M ulticolumn 1 no . Current Av erage steam load: 5 00 kg/hr Peak load: 7 00 kg/hr

Parameter U nit C OIL TY P E S HELL TY P E B oiler Capacity Kg/hr 3 x 4 00 + 6 00

kg/hr 2 000

M ake T herma x + Fuelpack

J N M arshall

Production CapacityEff iciency ( N CV ) % Fuel Consumption L itres 576 L itres o f HS D 5 10 L itres o f FO Feed Water T emperature

*C 6 0 *C 8 0 -9 0*C

Dryness Fraction % 6 0 -7 0 % 98 %

Performance and Specific fuel consumption

Parameter C OIL TY P E B oiler

S HELL TY P E B oiler

FO consumed f or 100 ml production 8 00 lit 4 5 0 litFO consumed f or 5 00 ml production 1100 lit 76 0 litHeating period f or 100 ml ( A utocla v e) 55 M inutes 3 5 M inutesHeating period f or 5 00 ml ( A utocla v e) 66 M inutes 5 0 M inutesDistilled water output f rom M ulticolumn 2 00 L itres 2 75 -3 00 L itresT emperature attained in M ulticolumn 1 4 5 *C 1 5 3 *C

Problems f aced with C OIL TY P E boilers:y N ozzle Choking, cleaning required during e v ery shi f ty Coil Choking, R egular maintenancey Wet steamy Poor response to load f luctuations


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Process B ene f its with S HELL TY P E B oilersy Dry steam & High process e ff iciency . y R educed batch timingsy Ex pensi ve maintenance downtime a verted .


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Budgetary Quote

SL.NO

.

ITEM DE SCR IPTION QTY Approx. Total Price

1. NATU R AL Gas fired boiler 2000kg/hr F&A100 C operating at 10.5kg/cm^2 pressure

1 27,00,000

2 High pressure Gas Train 1 3,50,000

2 Online Boiler Efficiency Monitoring SystemEFFIMAX 2000

1 11,00,000

Boiler House C hangeover 41,00,000

3 Pressure reduction S tations(IV, M S , P C 01,S trainer, P R V)

3 6,00,000

4 C ompact S team Trap Modules(P C 01) 5 1,10,000

5 C ondensate R ecovery System(FV, PPPPU, DH) 1 5,00,000

Plant Utiliasation and R ecovery 12,10,000

Total investment for Boiler House= Rs.41,00,000Total Savings = Rs. 19,00,000ROI = 22 months


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PARTIAL LIST OF CONVERSIONS

Sr. No. Plant Industry Replacement Measure

1

Dr. Reddy's Lab.

Hyd.

Pharma 3x 600 replaced with 3

TPH IBR

230 lit/hr Diesel- 164 lit/hr FO

2

Miami Pharma.Pune

Pharma 400 x 3 nos + 600 x 1no,replaced with 1120

kg/hr x 1no IBR

300 ltrs/day of FO with additionalsteam using equipment

3

HarmanFinoChem,

Aurangabad

Pharma 600x 2nos replaced by2000kg/hr x 1 nos

43500 lts Diesel/month- 39925ltsFO/month

4

Bal Pharma, pune Pharma 400 x 3nos + 600 x 1nosreplaced by 2000kg/hr x

1nos

576lts of HSD to 510 lts of FO

5

Cipla Patalganga Pharma 850x 2nos replaced by2000kg/hr x 1nos

50Kl/month LDO to 45Kl/month FO

Grand Organics,Goa

Pharma 600 x 1nos + 850 x 1nosreplaced by 1100Kg/hr

25000lts of FO to 20000lts of FO

Documents

Unichem Lab 2