Thirumalai

Chemicals
Ltd.,
Thirumalai
Chemicals
Ltd.,
Thirumalai
Chemicals
Ltd
Ranipet
Ranipet

Ranipet, India

History of Thirumalai Chemicals Limited

Public limited Company

Started in the Year 1973
Sales Turnover Rs.400 crores
Global Leader for all products
TCL India & TCL Malaysia together has the largest capacity in the
world to produce Maleic Anhydride

Our products & Applications

Phthalic Anhydride 87, 000 Tons / Year

Paints

Polyester Resins
Plasticizers

Maleic Anhydride 17, 750 Tons / Year

Polyester Resins

Pharmaceuticals

Paints

Malic Acid
Food Acids 17, 000 Tons/Year
Soft Drinks
Candies

Pharmaceuticals

For Manufacturing Cheese

Fumaric Acid
Food Acids 17, 000 Tons/Year
Soft Drinks

Animal Feed

Candies

Organizational Growth
1997-98

1997-98

PAN 87,000 TPA

1997-98

FOOD ACIDS
17,000 TPA

MA 17,750 TPA
1990-91

MA 11,000 TPA

1991-92

1988-89

PA 25,000 TPA

FOOD ACIDS
1,000 TPA

1985-86

PA 19,000 TPA
1974-76

PA 6000 TPA

1973

1988-89

MA 1,000 TPA

ISO
14001:
2004

AWARDS AND
MILESTONES

ISI
Fumaric
Acid
HACCP
ICMA
Energy
Award
ISO
9001:2
000

ISO
14001:
1996
INEA
ISO
9002

1994

2006

2004

2003

2002

2001

2000

1995
INEA International Export Award

Importance of
Energy Management in TCL

Importance of Energy Management in TCL

TCL, being a Petro chemical Industry, is energy Intensive.
Energy cost contributes to about 3-4 % of the manufacturing costs
and is next to raw material cost.
The increased competition and raising prices of Power & Fuel
demands cost reduction in all respects for survival.
The prime focus is on Energy cost reduction through efficient waste
heat recovery, conservation measures and productivity improvement.
The main emphasis is towards Generation, Distribution and Usage
of Steam & Power as efficiently as possible.

Establishment of Energy Cell in TCL

Opportunities to implement energy conservation activities.

Formed a separate energy cell in the Year 2000.
Energy Cell comprises of an Energy Manager & Energy Engineer.

Activities of Energy Cell in TCL

Energy Cells main role is to Facilitate Energy Conservation
activities to optimize Energy Consumption
Activities:
1. Data collection:
a. Steam generation & consumption
b. Power generation & consumption
c. Fuel consumption
2. Preparation of Steam & Power balance for entire network
3. Calculation of daily energy cost through a separate Energy Module for
various products
4. Efficiency calculations of high energy generating equipments
like Turbines, Turbo blowers & fired heaters.

Activities of Energy Cell in TCL

5. Analyzing & taking immediate Corrective actions for daily
deviations

6. Monitoring of instrument air generation & consumption

7. Maintaining records for daily deviation to eliminate for future
occurrences
8. Calculating daily losses (venting & failure losses)

Contd

ENCON Methodology

ENCON Methodology
Idea
Generation

From
Energy Cell
From
HODs,
Engineers &
Supervisors
From
TPM circles
Through
Suggestions

Feasibility
Study

By HODs or
energy cell
Preparation of
detailed report
( Investment, cost,
benefit ,Payback etc)

Implementation

Audit &
Monitoring

Approval
by
Management

Audit by
Energy cell

Implementation
by
Concerned HODs

Report Generation
On Actual saving
& Expected Saving

Report Generation
after Completion

Monthly Monitoring
the Performance
by Energy cell

Energy Conservation Activities

Carried out
in Electrical Systems

Energy Conservation Activities

1.Stoppage of unnecessary & Idle running drives

2. Conservation using V.F.D.
3. Power Reduction using Pulley Changing.
4. Capacitor provision to improve power factor
5. Frequency reduction in the generating point
6. Voltage Reduction in Feeder from 500V to 415V
7. Segregation of Low & High Head Cooling Water Pumps.
8. Installing Energy Efficiency Motor.
9. Energy efficient lamps
10. Providing LED Lamps for Panel Indication.

Various Power Reduction Activities

" Variable frequency drive

- Speed Reduction

"

Downsizing the motors

- Lower Capacity motor

"

Pulley size changing

- Speed reduction of Drives

"

Energy Conservation in Cooling Water System

Case Study

Energy conservation in
Hot Oil Circulation Pump using VFD

I - VFD Installation in Hot Oil Pump (PA Plant)

Before Condition:
During re-cooling, hot oil is re-circulated bypassing

SWC. Hence scope for Power reduction.

HOT OIL SYSTEM

SWC-1

HOT OIL TANK

SWC-2

SWC-3

SWC-4

SWC-5

Running amps : 24 amps

Running Power : 17.0 Kw
Frequency
: 50 Hertz

After Condition:

Power reduction can be achieved by reducing the speed by reducing

the

frequency.
Interlocked with the recycle valve.
The flow at the reduced speed is sufficient to maintain the

hot oil temperature.

SWC-1

SWC-2

SWC-3

SWC-4

SWC-5

VFD

HOT OIL TANK

Running amps : 7.5 amps

Running Power : 5.0 Kw
Frequency
: 30 Hertz

RESULT
MELTING CYCLE

RECOOLING CYCLE

Running amps : 24 amps

Running amps : 7.5 amps

Running Power : 17.0 Kw

Running Power : 5.0 Kw

Frequency

Frequency

Power Savings

: 50 Hertz
:

: 30 Hertz

12 KwHR = 0.288 Lakh kwh/Annum

Energy management
Case Study
Elimination of Power Loss
in MA plant

Speed 1440 rpm

BEFORE

Motor 37 KW

30-40 %

Discharge valve opening 30%-40%

Suction line

Oxidation tempered
water pump

37 KW

1440 RPM

Using VFD RPM reduced to 960

AFTER

Satisfies the process requirements

70-80 %

Motor changed to 960 RPM

Suction line
18.5 KW

Oxidation tempered
water pump

960 RPM

COST BENEFIT

Project cost
Rs 0.5 Lakhs

Saving / month
Rs 0.8 Lakhs

Pay back 20 days

Energy management
Case Study

Power Reduction in Blowers

(FUMARIC ACID PLANT)

Process of Fumaric Acid Drying

AIR EXHAUST TO FINES RECOVERY
SYSTEM

AGITATOR
WET
MATERIAL
INLET

FUMARIC BED

PIN AGITATOR

15 BAR STEAM
PREHEATING ZONE

HEATING ZONE

AIR
PREHEATER
HOT AIR DUCT
DRYER
BLOWER

150 deg C

COLD AIR
DUCT

COOLING ZONE

BEFORE
HIGHER CAPACITY OF BLOWER
SPEED-1440 RPM
Damper opening 30%
DAMPER

30 %
OPEN

PULLEY
310 mm
1440
rpm

DRIER

AFTER
DAMPER OPENING INCREASED TO 70% BY REDUCING THE SPEED TO
920 RPM BY CHANGING THE PULLEY SIZE TO 400 MM

DAMPER
PULLEY
400 mm
920 rpm

70 %
OPEN

Blower

Motor

Pulley
(400 mm)

DRIER

RESULTS

REDUCTION IN POWER CONSUMPTION

KW/hr
30
28
Good

25

20

15
13
10
BEFORE

AFTER

BENEFIT
4

Lakhs/ Annum
3.9

GOOD
3

0
BEFORE

AFTER

ROI

INVESTMENT
Rs. 0.05 LAKHS

BENEFIT
Rs. 3.9 LAKHS

ENERGY MANAGEMENT
Case Study

Energy conservation in
Cooling water system

BACKGROUND
High Power consumption in Utility cooling water system during part load
operation

ANALYSIS
Three High capacity ( 90 kW ) Cooling water pumps are in operation for
serving Two Turbo Blowers & one Turbine generator.
During Part load operation ( One TG & One Turbo blower ) all three high
capacity pumps has to run.
No Low capacity pumps is available to satisfy part load operation
System studied and provided one low capacity 55 kW cooling water Pump.

KAIZENS
After

Before
To Turbo Blowers &
Turbine

To Turbo Blowers &

Turbine
FULL
OPEN

50 % OPEN
90
kW

90
kW

90
kW

90
kW

55k
W

RESULTS
Power Consumption
kW / hr
280

250

260

240

220
215

200
BEFORE

AFTER

BENEFIT
16

Saving RS in lakhs / Year

15.12
14
12
10
8
6
4
2
0

0
BEFORE

AFTER

Energy Conservation Activities

Carried out
in Thermal Systems

Energy Conservation Activities

Implementation of Co-Generation System

Introducing new Flash Drums
Insulation of Chimney
- To Reduce Flue Gas Temperature from 220*C to 200*C
Increasing Productivity thereby increasing Steam Generation
Steam Trap Performance Checking using Ultra Probe-2000
Process Modification in Distillation Batches
- Reduction in Steam Consumption
Optimizing Air PreHeater Steam Consumption.
Steam Leak Arresting using a separate Team

Energy management
Case Study
Implementation of
Co-Generation System

Co-generation system in TCL

Contd

Heat Recovery Unit of Reactors

40 Bar
(HPS)
Superheater
40 Bar
(HPSH)
Turbine

15 Bar
(MPSH)
15 Bar
(MPS)
Consumers
Condensate

Turbo Blowers
DSH
Consumers

6 Bar Steam

4 Bar Steam

4 Bar from
Distillation
Condenser

4 Bar
Flash Drum
Condensate

Condensate
6 Bar
Flash Drum

Boiler feed
water Tank

Co-generation system

Our processes are designed to utilise all heat liberated from

exothermic reaction
Generation of high pressure steam (40 bar)
Meets both Process heating & Power requirements
Our process requires steam at various Pressures.
Installed a 5 MW Turbo generator (Extraction cum Condensing )
The extraction steam meets process requirements.

Contd

Best Practices in Co-generation system

Contd

Steam driven Turbo blowers meet our process air requirement

Medium pressure flash drums in condensate network, to recover
.

steam at 6 bar.
Generation of 4 bar steam from distillation condenser
Recovery of 4 bar steam from Medium pressure condensate,
through flash drum
4 bar steam is used for process heating
All the steam condensate after heat recovery is diverted to Boiler
feed water tank in order to utilize the sensible heat.

Case Study

Energy conservation in
Steam Network
Implementation of New HP Flash Drum

BACKGROUND
Generation of 4bar Steam from 40bar,15 bar condensates.
Generation of 4 bar steam is in excess.
Venting of 4 bar steam.

ANALYSIS
In normal Plant operation,venting of 4 bar is resulted.
During the shutdown period of downstream plants,venting of
4bar steam is high.
6 bar demand for plant heating is met by letting down from
15bar to 6 bar .
So it is planned to flash 40,15bar condensates into a new
Medium pressure flash drum to generate 6 bar steam.

4 Bar steam

Before:
4 Bar Steam Vented to Atmosphere
High Pressure Condensate

Flash
Vessel

Low Pressure Condensate

Condensate

After:
6 Bar Flash Drum Introduced

Low Pressure
Condensate

4 Bar
Flash
Vessel

6 Bar steam

4 Bar steam

High Pressure
Condensate

Condensate

6 Bar
Flash
Vessel

Condensate

RESULTS
Venting of 4 bar steam is minimized
Cost Saving is Rs.3.5lakhs/month.
Horizontal Implementation in another Plant.
BENEFIT

In v e stm en t
R s 1 .0 0 L a k h s

S a v in g
R s 3 .5 L a k h s

Extent of Team Work in

ENCON Activities

Contribution of Workmen / Supervisors

Identifying / eliminating energy related abnormalities through O&M
Concept
Monitoring & taking corrective actions through Daily Work management
Concept of Small group activities has given a clear approach & idea on
loss elimination techniques
Most of the abnormalities like steam leaks,Instrument air leaks,
Condensate leaks are attended by Operators themselves

Contribution of Workmen / Supervisors

Contd..

Steam traps inspection & skin temperature measurements are being carried
out by respective plant supervisors
Energy week & Suggestion scheme motivates our employees to give
innovative & creative suggestions
Every employee is involved in one or other of the energy conservation
activities implemented in his plant which gives them a sense of
accomplishment

Overall Results

Specific Energy Consumption

in Million K.cals / MT of Product

MILLION K.cals / MT
3.00

2.00
2.00

1.46

1.10

1.16
1.01

1.00
0.63

0.00
2000-01

2001-02

2002-03

2003-04

2004-05

2005-06

Specific F.O Consumption (Lit/MT)

LTS/ MT
180
163.6
160
140

124.7

120
103

100.0
92

100
80

56

60
40
20
0
2000 -01

2001 -02

2002 -03

2003-04

2004-05

2005-06

Specific H.S.D Consumption (Lit/MT)

LTS/ MT
40
36.2
35

30

23.0

25

20

15

13

12.6
9

10

6
5

0
2000 -01

2001 -02

2002 -03

2003-04

2004-05

2005-06

Specific Consumption - EB

KW/ MT
70

60

63

50

40
35
30

26

27

26

20

10

12

0
2000 -01

2001 -02

2002 -03

2003-04

2004-05

2005-06

Specific Water Consumption (KL/MT)

(KL/MT)
14

13

12.7

12
11.4

11.6
10.9

11

10

8.6

6
2001-02

2002-2003

2003-2004

2004-2005

2005-2006

Future Improvements
To eliminate 4 bar venting (excess) steam, Planned to install a new
boiler feed water preheater
Horizontal Implementation of High & Low Head Cooling Water
Segregation in another Plant.
Installation of new SBC to increase the productivity
Replacement of Electric heater with Steam heater in the Air
drier unit

Thank you