10 YEARS OF ENERGYCONSERVATION PROGRAMMEIN AN EDBILE SALT REFINERY

Plant Operation Scenario

• Plant Capacity Utilization reduced from 87% to43%

• Specific Energy Consumption (Mega joules/MT)increased by 42%, mainly due to lower capacityutilization and fuel switch from liquid to solid.

• But for the Energy Conservation measures, thespecific energy consumption would have beenhigher by another 10% for the period.

Impact of Energy conservationProgram

• Maximum Demand Recorded, reducedfrom 435 KVA in 2001-02 to 246 KVA in2011-12; 43% reduction.

• Contract demand with Grid Powerreduced from 600 KVA to 380 KVAduring the corresponding period.

• MD quota was fixed at 315 KVA by GridPower Supplier in 2008 due to PowerShortage.

Impact of Energy conservationProgram

• Power Consumption norm was reduced from 33units/MT in 2001-02 (for 87% of Installedcapacity utilization) to 25 units/MT in 2011-12(for 43% of Installed capacity utilization);

• Specific Energy Cost (Rs/KJ) reduced by 21%mainly due to fuel switch from F.Oil to Biomass.

• Specific Energy Cost per Mt of Productionincreased only by 12% in spite of 42% increasein Specific Energy Consumption.

Electrical Energy Norm Variation with Productivity and Capacity utilization

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CapacityUtilization %

ProductivityMt/hr

Power NormsUnits/Mt

Electrical Energy Consumption Norm Variation with Capacity Utilization

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Electrical Energy Norms vs Productivity

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ProductivityMT/Hr

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Consumption of Fuel for Drying

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Fuel

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Fuel Oil Lit/MTWood Kg/MT

• Grid Energy Price revision in March 2003 and in August 2010.• Variation in Grid Cost is due to charging Fixed MD Charges on the total Grid

Energy units consumed.

Price Movement of Energy & Fuels

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Diesel Rs/litFuel Oil Rs/litWood Rs/UnitGrid Energy Rs/unit

Movement of Max Demand

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Max MD reachedin KVA

MD Quota in KVAsince 2008

Contract Demandin KVA

• Power Cut introduced in 2008-09

DG Utilization %

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DG %

Specific Energy Consumption of Various Types of energy(MJ/MT)

• Overall Sp. Energy Consumption has gone up due to lower capacity utilization and use ofBiomass in place of Oil.

• The efficiency of bio mass system is lower but cost effective.

Sp.Energy Consumption of Types of Energy (MJ/MT)

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Sp.El.EnergySp.Fuel for PowerSp.Fuel for H.AirSp.Biomass for H.airSp.Fuel for HandlingOverall Sp.Energy

Energy Cost

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Sp.Energy ConsumptionMJ/MtEnergy Cost Rs per MT

Energy Cost Rs/KJ

Capacity Utilization vs Energy ConsumptionWith Trendline

Capacity vs Energy Data

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Capacity %

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1995-022002-12Linear (1995-02)Linear (2002-12)

Capacity Utilization vs Energy Consumption-Linearized Curve Fit

Capacity Utilization vs Energy Consumption Curve Fit

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Capacity Utilization in %

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1995 to 20022002 to 2012

Capacity Utilization vs Energy Consumption(MJ/MT)

Capacity Utilization % vs Sp.Energy MJ/MT

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y M

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T

1995-022002-12Expon. (1995-02)Expon. (2002-12)

Energy Cost Saving• Energy Bill from 2002-03 to 2011-12 - Rs. 1473 lakhs• Saving due to Energy & Cost saving measures during

the period - Rs. 744 lakhs• Energy Bill without Saving measures - Rs. 2217 lakhs• Savings in Energy Cost for the period – 33.56%• Investment for Energy & Cost Saving measures

during the period - Rs.82 lakhs

Year wise Implementationof Energy Conservation

Measures

FY 2002-03Wet Hammer Mill for Raw Salt Crushing Qty -1No.:

75 KW Motor: Motor Circuit Changed from Star Delta toStar Mode.Motor was replaced with 55 KW and then to 45 KWmaintaining the Operating Motor Circuit in Star Mode.

Mills for Dry crushing of Over size refined Salt;Qty – 4 Nos.

All motors (each 22 KW) were changed over to StarMode Operation.The salt feeder was removed and feed by gravity flowwas introduced. Four numbers of 1.1 KW (total 4.4 KW)were removed from service.No Investments

FY 2002-03

Agitators:Two Agitators – 15 KW each, One Agitator-7.5 KW and One agitator 109 – 1.5 KW werechanged over to Star Mode OperationDryer System:

The excess capacity in the fluid bed dryer wasreduced by selectively blocking the air nozzlesby about 33% in the Heating zone and about50% in the Cooling Zone. This reduced theFluidizing Air requirement in both the zones.

FY 2002-03

• After many trials on the rationalizationof motors, the following changes weremade– Hot Air Blower speed was reduced and 75 KW

motor was replaced with 55 KW motor.– Cooling Air Blower speed was reduced and 55 KW

motor was replaced with 45 KW motor– Exhaust Air Blower speed was reduced and 75

KW motor was replaced with 55 KW motor.• No Investments

FY 2003-04Exhaust Air Blower speed was reduced and 55KW motor was replaced with 45 KW motor.Cooling Air Blower speed was reduced and 45KW motor was replaced with 22 KW motorTotal Investment on New motors – Rs.1.75 lakhsOne set of slurry pumps were replaced withlower head ( pressure) & 15 KW motors werereplaced with 7.5 KW motors.- InvestmentRs.1.89 lakhsInvestment in Wood fired Hot Air Generator forRs.31.5 lakhs to replace Oil fired system.

FY 2004-05

Furnace Oil fired Hot Air Generator systemwas replaced with Wood Fired System.The 60 KW Motor of the Hot Air Fan of theWood fired system was provided withVariable Frequency drive as against the 75KW motor of the Furnace Oil fired system.Lower Capacity Cooling Air Blower with 15KW was installed in place of old blowerwith 22 KW.

FY 2005-06

Wood Fired Hot Air GeneratorSystem was modified to

improve its performance.

FY 2006-07

Plant Capacity Utilization wasincreased and Energy Consumption

was observed for identification offurther improvements

FY 2007-08Old water cooled reciprocating Aircompressors were replaced with AirCooled Screw Compressors. Cooling watersystem was removed.The heatless air dryer was replaced withrefrigerated air dryer.Wood fired Heater System was furthermodified to improve performance.Automatic Power Factor Control Panel wasrevamped and MD controller was installedin the Main LT Distribution Panel.

FY 2008-09• Variable Frequency Drives were provided

for the Cooling Air Blower, Exhaust AirBlower and new drive was provided for HotAir Fan of the Wood fired system.

• The existing 45 KW motor of Wet HammerMill was replaced with 37.5 KW. It isoperated on star mode.

• New Fork Lift, replacing 13year old ForkLift, was commissioned. Reduction inDiesel consumption.

FY 2008-09

• High Capacity 750 KVA DG set wasreplaced with 500 KVA DG set for betterload factor and fuel consumption.

• Four Old Pin Mills (22 KW motor each)for dry salt crushing were replaced withTwo New Hammer Mills. (22 KW motoreach). They are operated on star mode.

FY 2009-10

15 old motors were replaced with newmotors.Wood fired furnace modification.Productivity improvement was takenup to improve the Specific EnergyConsumption.

FY 2010-11

Energy Audit was carried out in July 2010.Capacitors 25 KVAR was added each inMCC 1 and MCC 2 to improve the Powerfactor and reduce the Maximum Demand.Centrifuge Rotor Motor starting methodwas changed from DOL to Star Delta toreduce starting current and MaximumDemand.

FY 2010-11The Productivity improvementprogrammes were continued.High Capacity 14.5 Mt/hr fluidized Beddryer was replaced with 12.5 MT/hr Dryer tocommensurate with the currentproductivity levels for optimizing theenergy consumption.Old Wet Hammer Mill with 37.5 KW motorwas replaced with New Wet Hammer Millwith 22 KW motor.

FY 2011-12Due to improvement in Input Raw Salt Quality, onewashing stage was eliminated and the equipmentswith total installed Motors of 30KW were removedfrom service.Electrically operated Forklift was introduced alongwith the existing Diesel Operated fork Lift toreduce the diesel Consumption. Investment Rs.4lakhsEnergy Audit was carried out in October 2011 foridentifying the scope for further reduction inEnergy Consumption.Old Luminaires were replaced with new energyefficent luminaires

Further Potentials for energyreduction

Soft starters for Crusher motors.Compressor Optimization.Use of Lower height thickener.Wood Gasification Plant for Hot Air generation (underevaluation)Use of Radio Frequency Drying ( under evaluation)Motor rationalization and power factor improvement ofRaw Salt Unloading equipments.Reduction of Wood Consumption.

Thank You

PreparedBy

N.AnanthEA 9404