KESORAM RAYONA CASE STUDY

KESORAM RAYON

MANUFACTURER OF

- VISCOSE FILAMENT YARN- TRANSPARENT (CELLOPHANE PAPER)- SULPHURIC ACID- CARBON-DI-SULPHIDE- SODIUM SULPHATE

EMPLOYEE STRENGTH = 2800 (approx.)TURNOVER (2001-2002) = Rs. 129 CRORESISO-9002 & ISO-14001 COMPANY

LOCATED ON THE BANK OF RIVER BHAGIRATHI, ON42 HECTARES OF LAND, 60 KM NORTH OF CALCUTTA

OUR MAIN PRODUCTS

Viscose Filament Rayon Yarn Transparent (Cellophane) Paper

NORM FOR ENERGY USAGE

- ELECTRICITY

- STEAM

- WATER

Sl.

No.

Equip-ment

No.

Installed

No.

Run

RPM Motor

KW

Actual

KW

Hours

Run

KWH/

Day

STEP-1

STEP – 2

ELECTRICAL ENERGY

Improvement of Power Factor Sizing of motors so as to prevent running

on partial load. Soft starters to reduce the energy wastage

in high torque applications. Improved alignment, bearing condition. Vibration analysis, vibration monitoring.

Contd….

Step -2 (Electrical Energy contd…)

Proper sizing of pumps, to avoid thro- ttling of valves and consequent motor size reduction. Use of lumen-efficient light fittings. Deployment of energy efficient motors. Application of frequency inverters for changing speed/flow. On-Off level controllers to prevent continuous run of equipments.

THERMAL ENERGY (STEAM/COAL)

Increase in combustion efficiency of boilers. Heat recovery from continuous blow down

water of boilers. Preheating boiler feed water to 105oC/135oC Better condensate recovery. Application of proper design steam traps. Rationalisation of Steam distribution. Minimisation of HP steam usage by converting

ejectors to LP steam. Atomisation of Fuel and improvement of calci-

nation dryer.

REFRIGERATION

Segregation of usage as per temperature requirement. Pipeline sizing to avoid pressure drop. Installation of flow controllers to stop chilled water to equipments, once a predetermined level is reached. Replacement of shell and tube type heat exchangers by plate heat exchangers. Downsize refrigeration area to minimum required.

CRITICAL EXAMINATION

WHERE HOW MUCH WHEN HOW HOW ELSE WHY

STEAM

CONDENSATE

AIR

ELECTRICITY

CHILLED WATER

STEP - 3

TOTAL SYSTEMS APPROACH

SELECTION OF EQUIPMENTS

EMPLOYEE INVOLVEMENT

INTER UNIT VISITS

OPTIMAL CAPACITY UTILISATION

UPGRADATION OF TECHNOLOGY

ENERGY AUDIT

REGULAR MONITORING OF IMPLEMENTED PROJECTS

ENERGY AUDIT CONDUCTED BY

1. Tata Energy Research Institute2. National Productivity Council3. Balmer Lawrie & Co. Ltd4. M.K. Raju Consultants (P) Ltd5. Forbes-Marshall6. Mazda Croll Reynolds Process Systems7. Separation Engineers8. Confederation of Indian Industry (CII)

9. M.K. Raju Consultants (P) Ltd. (for the current year 2002-2003)

B.K. BIRLA GROUP OF COMPANIESENERGY POLICY

We shall strive for continuous energy economy through –

- Formulation of overall energy strategy and targets.- All round participation of all employees including casual and

contractor labours with total commitment from top management.- Improved capacity utilisation.- Upgradation of process, technology and equipment.- Better plant layout.

We shall maximise the Group’s synergy by way of sharing expertise,between the units, through inter-unit visits, zonal conference and audit by expert team.

As a part of our energy conservation and environmental strategy, we arecommitted to reduce specific energy consumption by 1% every year by2010. J.D. PALOD Chairman, Energy Conservation & Productivity Improvement Group B.K. Birla Group of Companies

MAJOR ENERGY CONSERVATION PROJECTS IMPLEMENTED

YEAR

NO. OF

PROJECTS

IMPLEMENTED

TOTAL INVESTMENT

RS. LAKHS

ANNUAL SAVINGS

RS.LAKHS

1994-1995 20 75.27 78.31

1995-1996 17 512.00 183.77

1996-1997 11 123.67 60.95

1997-1998 14 150.61 81.97

1998-1999 30 218.95 127.41

1999-2000 23 180.35 91.06

2000-2001 24 121.85 95.41

2001-2002 27 138.31 98.25

TOTAL 166 1520.99 817.13

TOTAL ELECTRICITY CONSUMPTION (LAKH KWH)

591

540560

539

507

434

461

357

300

350

400

450

500

550

600

94-95 95-96 96-97 97-98 98-99 99-'00 '00-01 '01-02

TOTAL ELECTRICITY PURCHASED (LAKH KWH)

199

154

138

9279

68

92

71

0

20

40

60

80

100

120

140

160

180

200

94-95 95-96 96-97 97-98 98-99 99-'00 '00-'01 '01-'02

AVERAGE MONTHLY MAXIMUM DEMAND (KVA)

4336

3730

4011

2548

3126

2621 2600

1940

1000

1500

2000

2500

3000

3500

4000

4500

94-95 95-96 96-97 97-98 98-99 99-'00 '00-01 '01-02

COAL PURCHASED (MT)

8431481675

8582581411

7825573657 74714

57893

40000

45000

50000

55000

60000

65000

70000

75000

80000

85000

90000

94-95 95-96 96-97 97-98 98-99 99-'00 '00-'01 '01-'02

SPECIFIC ELECTRICITY CONSUMPTION (RAYON YARN)

6328

5565

5241 5200 52215120

4767 4755

4000

4500

5000

5500

6000

6500

94-95 95-96 96-97 97-98 98-99 99-'00 '00-'01 '01-'02

SPECIFIC ELECTRICITY CONSUMPTION (TP)

3484

27452659

2601

2897 2889

2347 2348

2000

2200

2400

2600

2800

3000

3200

3400

3600

94-95 95-96 96-97 97-98 98-99 99-'00 '00-'01 '01-'02

SPECIFIC COAL CONSUMPTION (RAYON YARN)

4.234.08

4.47

4.133.94 4.03

3.323.56

3.00

3.50

4.00

4.50

94-95 95-96 96-97 97-98 98-99 99-'00 '00-'01 '01-'02

SPECIFIC COAL CONSUMPTION (TP)

6.34

5.94

6.5

5.615.69

5.8

5.61

5.75

5

5.2

5.4

5.6

5.8

6

6.2

6.4

6.6

94-95 95-96 96-97 97-98 98-99 99-'00 '00-'01 '01-'02

ENERGY CONSERVATION AWARDS

NATIONAL ENERGY CONSERVATIONAWARDS

(a) For the year 1995 (1st Prize)(b) For the year 1996 (2nd Prize)(c) For the year 1997 (1st Prize)(d) For the year 1998 (1st Prize)(e) For the year 1999 (1st & Special Prize) (f) For the year 2000 (1st & Special Prize)

(g) For the year 2001 (Excellence Award) (h) For the year 2002 (Excellence Award)

Kesoram Rayon

Sri J.D. Palod, President, receiving the National Energy Conservation ‘Excellence Award’ for the year 2002, from theHon’ble Vice Presidentof India.

MAJOR PROJECTS IMPLEMENTED IN 2001-2002SL.

NO.PROJECT DESCRIPTION

ANNUAL SAVINGS

(RS. LACS)

INVESTMENT

(RS. LACS)

1SMALLER CAPACITY FEED WATER PUMP

FOR BOILER NO.55.02 4.00

2

LP STEAM HEATER FOR BOILER NO. 4&5

FOR MAXIMIZING COGENERATION

POTENTIAL FOR ADDITIONAL ELECTRICITY GENERATION @ 3200 KWH PER DAY

40.06 20.00

3PROPER SIZING OF BUSBAR & TRANSFORMER

5.81 3.53

4INSULATION OF SIDEWALLS OF TP DRYER

3.20 0.85

5 ACID CIRCULATION PUMP FOR DCDA 1.83 2.64

6AXIAL FLOW TYPE FAN FOR SWITCH HOUSE

0.42 0.90

7NEW PUMP FOR STRONG LYE PREPARATION

0.17 0.50

8SOLUTION LYE PUMP REPLACEMENT IN SODA STATION 10 A/B

0.37 0.90

9TRIMMED IMPELLER FOR SOFTNER FEED PUMP

1.98 0.36

Contd..

SL.

NO.PROJECT DESCRIPTION

ANNUAL SAVINGS

(RS. LACS)

INVESTMENT

(RS. LACS)

10 PURE LYE PUMP OF STATION NO.16 0.12 0.40

11 AXIAL FLOW FAN FOR PULP GODOWN 0.51 0.90

12 REPLACEMENT OF OLD TRANSFORMERS 2.306 8.48

13 AUTO START & STOP FOR AFT. STATIONS 0.511 1.00

14THERMO-COMPRESSOR IN PLACE OF LOW EFFICIENCY TG-1/2

0.73 8.00

15UTILISATION OF 161 M3/DAY SPENT WATER FROM CALCINATIONS TO SPINNING

1.42 0.72

16

SAVING OF FRESH FILTER WATER IN BOILER HOUSE BY USING TP PLANT

SPENT WATER IN ESP SLURRY SYSTEM & ASH QUENCHING AREAS TO SAVE 977 M3/DAY

8.64 2.40

17REDUCTION OF TEXTILE LABORATORY AIR CONDITIONING AREAS

1.52 5.60

18TWO SPEED MOTORS FOR VISCOSE DISSOLVERS

12.33 36.00

Contd..

SL.

NO.PROJECT DESCRIPTION

ANNUAL SAVINGS

(RS. LACS)

INVESTMENT

(RS. LACS)

19COLOUR-80 TUBE LIGHTS IN SPG. & TEXTILE SECTION

2.71 3.83

20NEW WATER SPRAY PUMPS FOR TEXTILE OLD-CCR AIR WASHER

0.51 0.65

21REDUCTION OF WATER CONSUMPTION IN OLD AT

0.45 0.50

22 VFD FOR NEW AFT AXIAL FLOW FAN 0.74 1.50

23 AXIAL FLOW FAN FOR OLD AFT 0.64 2.25

24TEMPERATURE AND FLOW CONTROL IN AFTERTREATMENT

2.24 4.60

25

CONVERSION OF SPINNING MACHINE INTO CLOSED FRP BOX TYPE TO REDUCE ELECTRICITY CONSUMPTION BY REDUCTION OF SPINBATH CIRCULATION AS WELL AS ENVIRONMENT IMPROVEMENT DUE TO LESS HEAT USAGE

0.59 5.00

26 LIGHT WEIGHT POTS FOR 8 MACHINES 2.33 21.12

27 REDUCTION IN WEIGHT TO TAKE UP CUP 0.14 0.74

TOTAL 98.25 138.31

ENERGY CONSERVATION MEASURES FOR 2002-2003

Sl.

No.ENERGY CONSERVATION MEASURES

ANTICIPATED SAVINGS/YEAR

IN ENERGY VALUE INVESTMENT

RS. IN LAKHSLAKH

KWH

MKCAL RS.IN

LAKHS

01 NEW VAPOUR ABSORPTION HEAT PUMPS IN ENGINE ROOM

3.95 990 26.19 100.00

02 USE OF FURNACE OIL IN PLACE OF LDO IN SOLID WASTE INCINERATION

- 1.50 1.80

03 LOW CAPACITY TP SPINBATH PUMP 0.55 2.19 2.19

04 LOW CAPACITY PUMP FOR CS2 MELTER 0.05 0.22 0.90

05 CF LAMPS IN PLACE OF INCANDESCENT TYPE0.30 1.19 2.00

06 HIGH EFFICIENCY VERTICAL RIVER PUMPS 0.75 3.00 3.00

07 VARIABLE FREQUENCY DRIVE FOR RIPENING AIR WASHER FAN

0.23 0.91 1.50

08 DRYER INSULATION BOX - 321 0.84 1.00

09 AFTERTREATMENT SUMP PUMP 0.29 1.17 3.15

10 TIMER FOR EXHAUST FAN 0.09 0.38 0.20

11 REPLACEMENT OF QC EXHAUST FAN 0.08 0.32 0.25

TOTAL 37.91 115.99

ENERGY CONSERVATION MEASURES FOR 2003-2004

Sl.

No.ENERGY CONSERVATION

MEASURES

ANTICIPATED SAVINGS/YEAR

IN ENERGY VALUE INVESTMENT

RS. IN LAKHSLAKH

KWH

MKCAL RS.IN

LAKHS

01 POWER PLANT REVAMPING AND RATIONLISATION OF BOILER & TURBINE

19.71 108610 705.02 1703.00

02 SPINNING POT SPRAY SYSTEM MODIFICATION

0.08 0.35 0.20

03 ACID CIRCULATION PUMP FOR DCDA

0.13 0.51 2.80

04 TEMP. & STEAM FLOW CONTROLLER IN AFT DRYER

- 544 2.24 4.60

05 HOTWELL PUMP FOR TP COOLING TOWER

0.65 2.63 2.50

06 CARBON FIBRE POTS FOR 8 MACHINES

0.58 0.14 0.74

07 UPGRADATION OF ILLUMINATION SYSTEM

7.10 - 10.50 28.00

TOTAL 721.39 1741.84

ENERGY CONSERVATION TARGETSPECIFIC POWER CONSUMPTION

(KWH/TON)

ACHIEVED IN

2001-2002

TARGET FOR

2002-03 2003-04 2004-05

RAYON YARN 4755 4500 4400 4350

TRANS. PAPER 2348 2200 2150 2100

SULPHURIC ACID 47 45 44 44

SODIUM SULPHATE 125 120 119 119SPECIFIC THERMAL ENERGY CONSUM-PTION (MKCAL/TON)

ACHIEVED IN

2001-2002

TARGET FOR

2002-03 2003-04 2004-05

RAYON YARN 15.66 14.50 14.25 14.00

TRANSPARENT PAPER 25.30 24.50 24.00 23.50

SODIUM SULPHATE 1.50 1.40 1.35 1.30

A FEWCASE STUDIES

STATIC INVERTOR IN PLACE OF ROTARYMGSET CONVERTORS (Exhibit – 1)

ELECTRICITY CONSUMPTION OF MGSET = 39000 KWH/DAYELECTRICITY CONSUMPTION WITH INVERTORS = 33000 KWH/DAYINVESTMENT = RS. 290 LAKHS

EARLIER SYSTEM - MG-SETSPINNING POTMOTOR SUPPLY FREQUENCY = 123 TO 130 C/SROTORY CONVERTORS RATING = 2000 KVA

PRESENT SYSTEM - INVERTOR FOR HF

COUNTER FLOW COOLING TOWER FOR POWER PLANT (Exhibit – 2)

INVESTMENT = RS. 60 LAKHSANNUAL SAVING = RS. 55 LAKHS

APPROACH TEMPERATURE 4 TO 50C

APPROACH TEMPERATURE0.50C TO 10C

RESULTED IN INCREASE OF CONDENSOR VACUUM AND REDUCTION IN STEAM CONSUMPTION

HEAT PIPE HEAT EXCHANGER FOR TP-DRYER (Exhibit – 3)

HEAT RECOVERED = RS.2,40,000 KCAL/HOUR INVESTMENT = RS. 30 LAKHS ANNUAL SAVING = RS. 26 LAKHS

EARLIER SYSTEM - FRESH AIR, HEATED THROUGH STEAM COILS CIRCULATE TO DRYING CHAMBERS, MOIST VAPOUR OF DRYER EXHAUSTED TO ATMOSPHERE AT 930C

PRESENT SYSTEM - HEAT PIPE HEAT EXCHANGER DEPLOYED TO PREHEAT INLET AIR BY EXHAUST AIR OF DRYER

VFD FOR ACID PLANT ROOTS BLOWER(Exhibit – 4)

CAPACITY OF ROOTS BLOWER - 7000 NM3/HR AIR FLOW REQUIRED - 5000 NM3/HR FOR 50 TPD

INVESTMENT = RS. 26 LAKHS ANNUAL SAVING = RS. 24 LAKHS

AIR FLOW CONTROL THROUGH DAMPER & BYPASS

AIR FLOW CONTROL THROUGH VFD

WASTE HEAT RECOVERY OF ACID PLANT(Exhibit – 5)

H2SO4 OF 950C REQUIRES TO BE COOLED TO 650C FOR PROPER ABSORPTION

EARLIER SYSTEMCI CASCADE COOLERS, WHERE WATER IS SPRAYED FROM TOP & ACID COOLED. WATER DRAINED CONTINUOUSLY.

PRESENT SYSTEMPLATE COOLER TO EXTRACT HEAT & UTILISE IN RAYON PLANT, THROUGH INTEGRATION OF SUB-SYSTEMS.

LP SteamHeater

Rayon Prewash

Water

Steam

Condensate

450 gpm

To ETP

waterRayon

Final Wash

400 gpm

To drain

ACID COLLERWater

H2SO4 at 900C

H2SO4 at 700C

To drain

SYSTEM INTEGRATIONPRESENT SUB – SYSTEMS (Exhibit – 5)

RAYONFINAL WASH

ACID COOLERH2SO4 PLANT

RAYONPREWASH

Water at room temp.

H2SO4at90o C

Water at 70o C

SYSTEM INTEGRATIONRE-ENGINEERED SYSTEM (Exhibit – 5)

INVESTMENT - RS. 45 LAKHSSAVINGS - RS. 4.7 LAKH KCAL/YEAR

- 3200 CM WATER/DAY

PAYBACK - 21 MONTHS

SULPHUR RECOVERY PLANT (Exhibit – 6)

EARLIER SYSTEM - TAIL GAS OF CS2 REACTORS -SCRUBBER FOR H2S, TRACES OF CS2USING NaOH OF 14.5 TONS/MONTH.RESULTANT Na2S – TREATMENT IN ETP

PRESENT SYSTEM - RECOVERY OF SULPHUR OF 300-400 KGPER DAY

INVESTMENT - RS. 46.00 LACSANNUAL SAVING - RS. 18.00 LACS

REDUCTION IN AIR CONDITIONING VOLUME(Exhibit – 7)

ANNUAL SAVING - RS. 2.10 LACSINVESTMENT - RS. 5.60 LACS

FALSE ROOFING TO REDUCE HEIGHT FROM 22 FT TO 12 FT IN RIPENING ROOM & LAB.

REDUCTION IN VOLUME - 14260 CFTREFRIGERATION LOAD REDUCED - 12 TR

THERMO COMPRESSOR (Exhibit – 8)

TURBINE-10.65 MW

TURBINE-20.65 MW

TURBINE-31.5 MW

PRDS

LP HEADER (2.5 KG CM2)

TO PROCESS 2.2 KG/CM2)(14 KG/CM2)TO PROCESS

STEAM HEADER 17.5 KG/CM2, 3700C

BEFORE

STEAM HEADER 17.5 KG/CM2, 3700C

PRDS

TO PROCESS

(14 KG/CM2)

TURBINE-31.5 MW

AFTER

(2.2 KG/CM2)TO PROCESS

TO PROCESS

(2.5 KG/CM2)

THERMO COMPRESSOR(Exhibit – 8)

STEAM SUPPLIED BY TG-1/TG-2 - 5.6 TPH(2.5 KG/CM2, 2600C)

PRESENT POWER OUTPUT - 5600X24 - 6110 KWH/DAY 22

STEAM USED BY THERMO COMPRESSOR -3.64 TPH OF 2.2 KG/CM2

1.96 TPH OF MOTIVE STEAM, AT 14.0 KG/CM2

PROPOSED POWER GENERATION FROM TG-3 - 3640X24 = 6240 KWH/DAY

14

REDUCTION IN MANPOWER COST, MAINTENANCE COST

INVESTMENT = RS. 2.00 LACSANNUAL SAVING = RS. 1.90 LACS

L.P.STEAM HEATER(PREVIOUS) (Exhibit – 9)

WATER

BOILER

HEAT GAINED FROM 40 TO 750 KCAL/KG

STEAM 3700C 17.5 KG/CM2

750 KCAL/KG

1000 C

PROCESS

400C

TURBINE

DEAERATOR

L.P. STEAM HEATER(PRESENT) (Exhibit – 9)

WATER 400C

LP HEATER

STEAM 3700C 17.5 KG/CM2

750 KCAL/KG

100 0 C

TO PROCESS

BOILER1250C

646 KCAL/KG2.0 KG CM2

DEAERATOR

TURBINE

L.P. STEAM HEATER(Exhibit – 9)

EXTRA STEAM PASSING THROUGH TURBINE GENERATES 2690 KWH/DAY

INVESTMENT OF PROPOSAL - RS. 20.00 LACS

ANNUAL BENEFIT - RS. 18.60 LACS

USING PLANT SPENT WATER IN BOILERASH QUENCHING (Exhibit – 10)

EARLIER SYSTEM• FRESH FILTER WATER WAS USED FOR BOILER ASH HANDLING SYSTEM

@ 60 M3/HOUR

PRSENT SYSTEM• T.P.PLANT WASTE WATER IS NOW USED FOR THE SAME

INVESTMENT - RS. 2.4 LACS ANNUAL SAVING - RS. 7.2 LACS

PROPER SIZING OF BUSBARS & TRANSFORMERS(Exhibit – 11)

- REPLACEMENT OF TRANSFORMER

- RELOCATION OF TRANSFORMER

- REDUCTION OF JOINTS IN BUSBAR

OF CARBON-DI-SULPHIDE REACTORS

PREVIOUS PRESENT

TRANSFORMER FULL LOAD

CU & FE LOSS10.34 KW 6.37 KW

LOAD DISTANCE 750 MTR 400 MTR

CABLE LOSS 10.60 KW 5.60 KW

NO. OF JOINTS 68 38

POWER LOSS DUE TO JOINTS 34 KW 19 KW

TOTAL LOSS 54.90 KW 30.97 KW

INVESTMENT - RS. 23.00 LACSANNUAL SAVINGS - RS. 8.30 LACS

ILLUMINATION EFFICIENCY(Exhibit – 12)

• 36 WATT SLIM TUBE LIGHTS• HIGH EFFICIENCY – CU CHOKES/ ELECTRONIC CHOKES• LIGHTING TRANSFORMERS• 70W/ 120W SON LAMPS

FUTURE PROPOSALTO REPLACE 3700 TUBE LIGHTS - BY 28 WATT FITTING

- BY CFL LAMPSTO REPLACE 220 SON LAMPS- BY 45W CFL LAMPS

PROPOSED INVESTMENT - RS.28.00 LACSPROJECTED ANNUAL BENEFIT - RS. 10.5 LACS

CARBON FIBRE SPINNING POT(Exhibit – 13)

No. of Spinning Machines 52

No. of Pot Motors 6880

Power consumption per Motor 190 WATTS

Weight of Steel Reinforced Spinning Pot 2.6 Kg

Weight of Carbon Fibre Reinforced Pot 2.2 Kg

Power consumption reduction 10 WATT

Annual Saving 5.89 Lac KWH

VAPOUR ABSORPTION HEAT PUMPS(Exhibit – 14)

EXISTING PROPOSED

ACTUAL MACHINE

RATING

170 TR/MACHINE

510 TR FOR 3 MACHINES

275 TR/MACHINE

550 TR FOR 2 MACHINES

COOLING WATER

REQUIREMENT365 CM/HR PER MACHINE

290 CM/HR PER MACHINE

NUMBER OF MACHINES RUN

1 M/C FOR 1 MONTH

2 M/CS FOR 8 MONTHS

3 M/CS FOR 3 MONTHS

1 M/C FOR 2 MONTHS

2 M/C FOR 10 MONTHS

VAPOUR ABSORPTION HEAT PUMPS(Exhibit – 14)

SAVINGSPOWER - RS. 15.78 LACSSTEAM - RS. 8.64 LACS

MAINTENANCE - RS. 8.00 LACS TOTAL SAVINGS - RS.32.42 LACS INVESTMENT - RS. 100 LACS

POWER PLANT(EXISTING ARRANGEMENT) (Exhibit – 15)

TOTAL POWER GENERATION - 115026 KWH/DAYCOAL CONSUMPTION - 211 TPD(B-GRADE)

POWER PLANT(PROPOSED ARRANGEMENT) (Exhibit – 15)

TOTAL POWER GEN - 124549 KWH/DAY

COAL CONSUMPTION - 185 TPD ( D/E GRADE)

INVESTMENT - RS. 1703 LACS

ANNUAL BENEFIT - RS. 705 LACS

A

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