Case study on Energy Saving Solutions for Fertilizer Plants-IGF... · Case study on Energy Saving...

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Case study on Energy Saving Solutions for Fertilizer Plants

February 16, 2016

Introduction

GE Study on Energy Efficiency

Efficiency Improvement… Analysis

GE’s Energy Saving Solutions

GE Digital Solutions

A

G

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D

A

We are at work as one company to invent the next industrial era.

And create things that build, move, power, and cure our world.

OUR MISSION

Rated AA+ with stable outlook by S&P

Only current DJIA company in original index

305,000 people

175 countries

$148.6B 2014 revenues

# 6 most valuable brand

GE Proprietary and Confidential

Digital Industrial Portfolio

POWER

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EMPLOYEES

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$18.7B 46K

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$24B 45K

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~$9B 13K

EMPLOYEES

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$8.4B 25K

EMPLOYEES

CAPITAL VERTICALS

$1.5B*

*Net income ** Revenue by year end 2016

TRANSPORTATION

$5.7B 13K

EMPLOYEES

HEALTHCARE

$18.3B 55K

EMPLOYEES

GE DIGITAL

~$6B**

2014 REVENUES


GE innovates, partners and develops technology solutions that help improve quality of life in India.

GE in South Asia

13,000+ employees

5,300+ engineers

JV with Indian partners like Wipro, SBI, BHEL & Triveni

First GE multi-modal manufacturing site

$1 Billion of global sourcing spend

10 Manufacturing sites

In India, for India, for world.


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GE © 2015 All Rights Reserved 2/16/2016

» Vast experience of GE NP – Playing a leadership role

» Single source supplier for both drivers and driven equipment

» Vast Product Portfolio

Gas Turbines & Steam Turbines

Centrifugal Compressors & Reciprocating Compressors

Turbo expanders- For power generation or as mech. drives

Pumps & Hydraulic power recovery turbines (HPRT)

Generators, Motors, Control systems

» Historic engagement with all major process Licensors and EPCs

» Customised solutions to meet any application/operational challenges

» Well established India foot print for spares parts and service support

GE Oil & Gas ………………….A PIONEER in the rotating machinery applications

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GE Oil & Gas – Experience in Fertilizer Industry

»More than 100 turbo compressor trains in 34 countries

»80+ years of technology leadership in the urea fertilizer production Market

»First compressor train in 1920 for 400 TPD plant

»Today Compressor train for 3800 TPD plants

»14 projects in Ammonia and Urea Synthesis in last 10 years

Extensive range, experience and expertise

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Study on Energy Efficiency – Customer Engagement

GE undertook a study to outline a roadmap towards energy efficiency and to enable customers to meet their specific energy targets.

Capturing Customer

Requirements

Visited customer site to discuss plant layout,

issues, collect necessary data, etc.

GE’s Internal Study

Evaluated possible energy saving solutions,

carry out calculations based on information

collected.

Solution Proposal by GE

Visit to customer with energy saving solutions proposal with benefits.

Our Approach…

Case Study 1 Urea production capacity of ~5500 MTPD with energy consumption of

~6.2 Gcal/MT of Urea

Case Study 2 Urea production capacity of ~3200 MTPD with energy consumption of

~5.2 Gcal/MT of Urea

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Efficiency Improvement

Reducing energy consumption of

existing process/equipment

Maximizing the throughput of existing unit

Independent GE Solutions

GE Solutions along with Energy Consultant

GE’s experience in products & services in O&G industry can contribute significantly towards reducing energy consumption of the existing process/equipment.

“The solutions identified through our case study are scalable and applicable across other fertilizer plants and designs.”


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~15% reduction in auxiliary load

for a Group I,II plant

~40% reduction in auxiliary load

for a Group III plant

“Optimizing auxiliary load consumption of plant is

relatively easier route towards energy efficiency”

Reduce energy consumption of auxiliary load

Reduce auxiliary load of a plant

Reduce fuel consumption of same

auxiliary load

GE Digital Solutions

Retrofit/upgrading existing equipment

Upgraded design to facilitate

plant/process change

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GE’s Energy Saving Solutions

4. Gas Turbine Performance Enhancement Kit (PEK)

For a typical 25MW GT, power output can be increased by ~4%

Retrofit/upgrading existing equipment

2. VAM (Chiller) in Air Compressor Inlet

Industry best practice…for maintaining consistent inlet air temperature.

~250 KW saving of power by installing at the inlet line of air compressors

1. Compressor train upgrade

Technology advancements in last 2 decades

~ 5-10% reduction in steam requirement of ST

& up to 5% capacity increase

3. Improve existing Hydraulic Turbine for higher power recovery

Capacity enhancement to recover power from bypass stream.

~250 KW of additional power can be recovered from the

bypassed stream

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GE’s Energy Saving Solutions Upgraded design to facilitate either plant/process change

1. Hydraulic Turbine in liquid Ammonia (NH3) stream

Typically liquid NH3 from synthesis loop is let down from ~180 to ~ 20 barg

~300 KW of power recovery from the stream with flow rate of 70-80 TPH

2. Turbo-expander in the Fuel Gas

Typically NG fuel is throttled from ~40 barg (depending on source) to ~5

barg for reformer.

~1.3-1.5 MW power recovery from this high pressure NG supply

3. Waste Heat Recovery from Flue Gas

Organic Rankine Cycle (ORC) system recovers waste heat energy from

Gas Turbines exhaust (or similar waste heat sources)

~500 KW power recovery from flue gas

4. Piping layout improvement

GE has engineering expertise and tools to perform piping pressure loss analysis to

improve performance of the equipment.

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GE’s Energy Saving Solutions Reduce fuel consumption of same auxiliary load

Gas Turbine based Captive Power Plant

Replacing Boiler with Gas Turbine to produce power can reduce the energy

consumption significantly

**Requires specific plant study to assess the benefits

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GE Digital Solutions Convergence of Operations Technology (OT) and Internet Technology (IT)

Response Max…Full maintenance-event management through Advisory Monitoring &

Diagnostics, Digital Warehouse Management and Digital Outage Planning

Reliability Max…Full equipment lifecycle management solution to minimize unplanned

downtime and optimize performance levels

Unified Operations… A holistic Asset Performance Management (APM) software

solution for faster diagnosis, improve asset performance & availability, and maximize profitability.

A host of digital solutions from GE to optimize an equipment, a unit, or a plant and can be extended at an enterprise level.

© 2015 General Electric Company

Advisory Monitoring & Diagnostics

Digital Warehouse Management

Digital Outage Planning

SERVICES

EXPERTISE

Early warning

Trip reduction

Remote tuning

Condition-based maintenance

Inventory digitization

Maintenance Engineer enabled by Software

ERP integration

Part in/out tracking

Security stock monitoring

Need identification

Part netting

Full demand management

Part kitting

CUSTOMER PORTAL

Response Max Capabilities

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• Increased operational visibility

• Improved process and resource efficiencies

• Optimized performance through scaling best practices

• Reduced cost and risk

Equipment OEM

agnostic

Rotating and static

equipment

Visibility at the

equipment, system,

plant, and fleet levels

Everything within the

context of the

Equipment

Unified Operations Capabilities

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Case study on Energy Saving Solutions for Fertilizer Plants-IGF... · Case study on Energy Saving...

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