Mr.

INTRODUCTION

Energy Conservation is one of the most important areas of Research and concern for Chemical Process Plants and other Industries. Resources are becoming more expensive day by day, and we need to design and rearrange our systems for Optimum use of Energy. Reducing wasteful use of resources is the key for cost cutting in today's Chemical Process Plants. Optimum use of Utilities facilitates savings of more than 40% and reduces monthly bills and hence decreases cost of Production.

In today's competitive market for Chemicals a rupee saved is a rupee earned and hence extra efforts need to be taken to investigate areas of concern in terms of wastage of resources and methods need to be devised to reduce the wastage and losses.

The Project at Clariant (India) Limited, Kolshet is dealt with Energy Conservation of the plant site. Utilities such as Water, Electricity, Steam & Ice were studied and their usage along with Energy Saving Techniques were suggested. The Site has 4 main Plants;

Dyes

Chemical

Leather Chemicals (LC)

Masterbatches

Maximum time & effort has been put into studying and optimizing the Energy Usage of the Dyes Plant.

ENERGY CONSUMPTION

FACT FILE

Services Tech.

Capacity 2001 2002 2003

Electricity

(Maximum Demand -KVA) 3428

100% 2524

74% 2564

75% 2420

71%

Water

(m3 / month) 47640

100% 33337

70% 32004

67% 32781

69%

Steam

(mT/month) 3600

100% 1402

39% 1245

34% 1019

28%

Ice

(mT/month) 759

100% 515

68% 518

68% 394

52%

ELECTRICITY CONSERVATION

The Utility Parameters used for defining economical use of electricity are;

* Total Consumption (kWh)

* Maximum Demand (kVA)

* Outages (hr)

* Power Factor

* Transmission Losses (%)

These Parameters have a maximum called the Budget Parameter and these have been estimated with Experience and Historical Information. The DYES Plant consumes around 10.7% of the total consumption of Electricity so a lot of Effort has been concentrated on Energy Saving Techniques in Dyes Plant.

2003

* Total Consumption (Kwh)

For the year 2003 the Budget parameter was 697979 KwH, but except the months of January and October (25 days) all 10 months has exceeded this budget parameter.

* Transmission Losses (%)

Also the Transmission losses as a percentage of the Total consumption have averaged at 6.85% every month and have remained within the budget parameter of 6.9%

* Maximum Demand (KVA)

The maximum demand (KVA) had a budget parameter of 2700 and no month has exceeded this parameter.

* Outages (hrs)

No parameter can be set for Outages (hrs) but in the month of October ,2003 the value has been 20 and throughout it has averaged at 4.34 hrs.

* Power Factor

The power factor value has remained constant at 0.99 for all months in 2003.

2004

Only the months of January & February are under study.

* Total Consumption (Kwh)

Due to the excess consumption of Electricity in the year 2003, the budget parameter has been increased to 731270 Kwh. The months of January & February are well within this parameter value.

* Transmission Losses (%)

The transmission losses Budget Parameter has remained at 6.90% but the month of January has exceeded this Value and has reached 7.13%

* Maximum Demand (KVA)

The maximum demand (KVA) has been constant at 2700 KVA and the demand for the months of Jan & Feb have remained within limits.

* Outages (hrs)

The outages for the month of January have been 8.5 hrs

* Power Factor

Power factor value has been constant at 0.99.

Monthly Bill:

On an average the monthly bill for Clariant (India) is around Rs. 30,50,000/-

This bill is divided into 3 broad areas:

* Clariant

* Novartis

* Colony

Clariant + Colony consume 54% of Total Consumption and the remaining 46% is consumed by Novartis

Colony accounts for only 3% of the total consumption, hence roughly about

Rs. 15,50,000 /- is the monthly bill for Clariant.

Energy Saving Techniques:

* Scheduling of Energy Intensive Operations during Night Zones