INDIAN PETROCHEMICALS CORPORATION LIMITED

Presentation on a Case study on

Energy Conservation Measures of
IPCL, Baroda
By
P. Nag, VP(Operations) &
A.K. Kewalramani, DGM(Technology)
 About IPCL
Date Event

March 22, 1969 IPCL Incorporated GOI as Petrochemical being highly Capital
Intensive
March-Nov 1973 DMT / Xylenes plants commissioned

March 28, 1979 Naphtha Cracker plant Commissioned. All Downstream plants
commissioned.
October 28, 1987 Acquired CATAD

July-Sept. 1992 Nagothane Complex – Gas Cracker, LDPE, MEG, PP, Low
Density Polethylene, Mono-Ethylene Glycol and Polypropylene
Plants were Commissioned & Stabilized.
Sep -Dec 1996 Gandhar Phase-I :VC/PVC, Chlor- Alkali, HDPE plants and
Captive Jetty at Jageshwar Commissioned.
March 30, 1998 NC – Cracker plant Expanded from 300 to 400 KTA Ethylene,
LLDPE Plant expanded from 160 to 220 KTA.
Sept. 1999 to Gandhar Complex – Phase-II : Cracker/MEG Plants
Feb.2000 Commissioned.
June 4, 2002 Disinvestment to RIL
 Location of three complexes
BC
NC
GC
IPCL, Baroda’s Cracker Plant view
 IPCL Performance

15000 13541 300

N e t P r o fit R s .C r .
G r o s s T u r n o ve r

9921 250
8524 274 200
10000
R s .C r

204 150
5000 100
107
50
0 0
2001 - 02 2002 - 03 2003 - 04
Net Profit Year Gross Turnover
WHERE GROWTH IS A WAY OF LIFE
 0
1
2
3
4
5
6
7
8
1991 - 92 7 .1

1992 - 93 6 .9

1993 - 94 6 .5

1994 - 95 5 .9

1995 - 96 5 .2

1996 - 97 5 .4

1997 - 98 5 .1

1998 - 99 5 .0

1999 - 00 4 .9

2000 - 01 4 .2

2001 - 02 4 .2
Energy Index (IPCL)

2002 - 03 3 .8

2003 - 04 3 .7
E.I. in MMKCAL / MT

2004- 05 3 .4
 Energy Cost Vs Manufacturing Cost

17.5
17.12
17
Energy Cost as % of Manufacturing Cost

16.5 16.34

16

15.5 15.36

15

14.5

14

2001-02 2002-03 2003-04

 ORGANISATION STRUCTURE
ORGANISATION STRUCTURE
Whole-Time-Director
Board Level

Sr. Vice Sr. Vice Sr. Vice Sr. Vice Vice Asst. Vice
President President President President President President
(Operations) (Materials) (Technology) (Engg. (Pers. & (Medical
Services) Admn.) Services)

Dy. General
Energy Manager
All Coordinators (Technology) --
Plants ( All Plants ) Energy Cell

Dy. Gen.
Manager(Technology) &
Manager ( Tech.)-Energy Cell)

Energy Cell Inception in 1982. Dedicated Group carry out ‘Energy

Management Activities’ of the Complex.
 Energy Management Strategy

™ Participative Approach :

¾ Energy Conservation Measures actions through Energy

Coordinators.

¾ Periodical Walk through Energy Audit of Plants by Committee.

¾ Interactive Workshops of Operation Groups.

¾ Monthly Performance Review Meetings.

¾ Monitoring and Optimisation of Major Utilities.

 Energy Management Strategy

™ Technology Selection :

¾ Considering Energy Efficiency of the Process.

™ Expert’s Involvement :

¾ Detailed Energy Audit of various Systems by External Reputed

Consultants.

™ Awareness Campaign :

¾ Declaration of ‘Energy Policy’.

¾ Organising of Training Programmes.

¾ Display of Bill Boards and Stickers on Revenue losses.
 IPCL ENERGY MEASURES

™ IPCL has carried out various Energy Conservation

measures at all Sites.

™ IPCL is the 1st Plant in India to go for Cogeneration

based CHP plant on a bigger scale.

™ IPCL is the 1st Plant in India to go HEN based on

Pinch Technology with an investment of Rs. 6 Crores
in late 80’s.

™ IPCL has invested Rs. 79 Crores in Wind Mills Project.

™ IPCL has the Distinction of receiving several ‘ National
Energy Awards ‘
 BACK GROUND OF ACRYLONITRILE PLANT

™ ACN Plant is one among the 40 plants of IPCL.

™ Annual Design Capacity of Plant is 30,000 MT.

™ Present Annual Production rate is 40,000 MT.

™ Exclusive Plant and only one in the whole of Asia &

Gulf.

™ It is Hazardous and very Safely Operated.

™ ACN is an Intermediate product for Acrylic Fibre &

Acrylates Production.
 ACRYLONITRILE PLANT
FUEL SAVING – A CASE STUDY

Feed

Reactor Section Waste Water-I Fuel for

Incineration

Waste Water-II
Recovery Section Incineration

ACN
Purification Product

HCN Purification Aceto Purification

 ACTIONS TAKEN FOR FUEL SAVING
Fuel
Year Consumption Actions Taken
MT/MT-ACN
1979-80 1.08 Lower Production rate.
1980-81 0.63 Improved production.
1981-82 0.36 Stripper bottom diversion (4.5 MT/Hr)
1982-83 0.32 to Bio-treatment instead of
Incineration started from 1982 and
completed in 1983 (phase wise). This
reduced the Waste Water Incinerated
from 3 T/T to 1.5 T/T (9 MT/Hr to
4.5 MT/Hr).
1983-84 0.36
1984-85 0.39
1985-86 0.41
1986-87 0.38
 ACTIONS TAKEN FOR FUEL SAVING

Fuel
Year Consumption Actions Taken
MT/MT-ACN
1987-88 0.36
1988-89 0.36 Hot Quench commissioned in 1988-89
1989-90 0.30 this reduced the Waste Water
Incinerated from 4.5 T/Hr to 3.5 T/Hr
and organic content (polymers)
increased from 5% to 22% by
adiabatic flashing in Quench column.
1990-91 0.28
1991-92 0.26
1992-93 0.26
1993-94 0.25
1994-95 0.29
 ACTIONS TAKEN FOR FUEL SAVING
Fuel
Year Consumption Actions Taken
MT/MT-ACN
1995-96 0.278
1996-97 0.231 Incinerator fuel changed from LSHS to
GAIL Gas. This improved Incinerator
firing and reduced excess air
requirement.
1997-98 0.236 Hot Alkali Digestion (HAD) (IPCL Patented
Process) established as ISBL treatment.
Reduced toxic content of waste water stream.
1998-99 0.252 ADVENT Process adopted for ET Plant.
1999-00 0.239
2000-01 0.168 Waste Water generation reduced from
1.10 to 0.76 T/T by increasing target TS %
from 20 % to 30 %.
 ACTIONS TAKEN FOR FUEL SAVING

Fuel
Year Consumption Actions Taken
MT/MT-ACN
2002-03 0.126 Waste water tank insulated thereby
retaining the stream temp. at 90 oC.
Reduction in Excess Air by closing of all
Air Register (dampers). Incinerator stack
temperature reduced from 740 to 710 oC.
2003-04 0.093 Further Reduction in Waste Water
generation from 0.73 T/T to 0.63 T/T by
increasing target T.S. % to 35 %.
Reduction in stack temperature from 710
to 680 oC based on observation of no
violation of Emission limit in stack
OVER THE 15 YRS PERIOD FUEL CONSUMPTION REDUCED
FROM 0.32 T/T TO 0.09 T/T.
 F U E L M T /M T - A C N

0.05
0.25
0.45
0.65
0.85
1.05
1.25
1.45
1.65
1.85
1979 - 80
1980 - 81
1981 - 82
1982 - 83
1983 - 84
1984 - 85
1985 - 86
Saving in Rs.,Lakhs

1986 - 87

Fuel T/T
1987 - 88
1988 - 89
1989 - 90
1990 - 91
1991 - 92
1992 - 93
1993 - 94
1994 - 95
1995 - 96
1996 - 97
1997 - 98
1998 - 99
1999 - 00
Saving in Rs. Lakhs
2000 - 01
2001 - 02
2002 - 03
FUEL CONSUMPTION TREND IN ACRYLONITRILE PLANT

2003 - 04
0
500
1000
1500
2000
2500
3000
3500
4000
4500

S a v in g in R s . , L a k h s
 CONCLUSION

ACHIEVED THROUGH VARIOUS SUSTAINABLE AND

INNOVATIVE MEASURES REDUCTION IN SP. FUEL
CONSUMPTION BY 85% SINCE PLANT STABILIZATION
IN 1981.

REVENUE SAVINGS ACHIEVED :

1. SAVING SINCE INCEPTION :Rs. 230 Cr.
2. SAVING IN LAST THREE YEARS :Rs. 6.89 Cr.
3. SAVING IN LAST YEAR :Rs. 1.32 Cr.
In this competitive era, You have to keep
on running even to stand where you are..!!

Either Small or Big, continual

improvement in Technology and Energy
Efficiency is the key for survival.
Take the Challenge…..
Sky is the Limit……!!
INDIAN PETROCHEMICALS CORPORATION LIMITED
 Energy Index of IPCL, Baroda
8
7.06 6.82
6.78 E.I. in MMKCAL / MT
7 6.46
6.05 5.88 E.I. in MMKCAL / MT
6 5.36
5.03
5
4.67 4.65 4.67 4.56

0
93-94 94-95 95-96 96-97 97-98 98-99 99-00 00-01 01-02 02-03 03-04 04-05