09 A Kalyanasundaram Thirumalai

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
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

Frequency
: 30 Hertz
RESULT
MELTING CYCLE
RECOOLING CYCLE
Running amps : 24 amps
Running amps : 7.5 amps
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
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

Carried out
in Thermal Systems
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
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
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09 A Kalyanasundaram Thirumalai

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Thirumalai

History of Thirumalai Chemicals Limited

Public limited Company

Our products & Applications

Phthalic Anhydride 87, 000 Tons / Year

Maleic Anhydride 17, 750 Tons / Year

For Manufacturing Cheese

PAN 87,000 TPA

Importance of Energy Management in TCL

Establishment of Energy Cell in TCL

Opportunities to implement energy conservation activities.

Activities of Energy Cell in TCL

Activities of Energy Cell in TCL

6. Monitoring of instrument air generation & consumption

Energy Conservation Activities

Energy Conservation Activities

1.Stoppage of unnecessary & Idle running drives

Various Power Reduction Activities

" Variable frequency drive

Downsizing the motors

- Lower Capacity motor

Pulley size changing

- Speed reduction of Drives

Energy Conservation in Cooling Water System

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

SWC. Hence scope for Power reduction.

HOT OIL TANK

Running amps : 24 amps

Power reduction can be achieved by reducing the speed by reducing

hot oil temperature.

HOT OIL TANK

Running amps : 7.5 amps

Running amps : 24 amps

Running amps : 7.5 amps

Running Power : 17.0 Kw

Running Power : 5.0 Kw

12 KwHR = 0.288 Lakh kwh/Annum

Speed 1440 rpm

Discharge valve opening 30%-40%

Using VFD RPM reduced to 960

Satisfies the process requirements

Motor changed to 960 RPM

Pay back 20 days

Power Reduction in Blowers

Process of Fumaric Acid Drying

REDUCTION IN POWER CONSUMPTION

To Turbo Blowers &

Saving RS in lakhs / Year

Energy Conservation Activities

Energy Conservation Activities

Implementation of Co-Generation System

Co-generation system in TCL

Heat Recovery Unit of Reactors

Our processes are designed to utilise all heat liberated from

Best Practices in Co-generation system

Steam driven Turbo blowers meet our process air requirement

Low Pressure Condensate

Extent of Team Work in

Contribution of Workmen / Supervisors