EXECUTIVE SUMMARY. Break up of Electricity Consumption . Scope of Study – Electrical System Network. Electrical System Network
1. Operation of Gas Turbines on naptha is not recommended due to reduced efficiency and maintenance issues
5. Compressed air leakage survey was done; list of identified leakage points have been provided
6. About 100m3/hr process condensate at 100°C comes out of process condensate stripper after transferring heat to incoming condensate; this condensate is cooled in cooling water heat exchanger before sending to DM water plant. This hot water can be used for a 300 TR absorption chiller for supplying cooling to control rooms or process applications.
7. The efficiencies of some process pumps in Ammonia – I & II and Urea – I & II have been reviewed
8. On request of plant managers, cooling water flows at a number of process heat exchangers were measured in Ammonia – I & II and Urea I & II
9. The transformer efficiencies of majority of the operating transformers have been estimated; no changes for efficiency improvement are envisaged in this area. The possibility of use of “low loss” amorphous core transformers for non-critical loads in future projects.
10. Measurements were made on majority of the working electric motors above 50 hp. The loading levels are generally good and no specific recommendations are made for motors.
1.Drinking water requirement in the factory is reported to be around 500 m3 per day which for the 1200 nos. of employees appear to be very high. Assuming that there is additional staff of contractors of about 600 and the company employees of 1200 (total 1800 persons) using water for drinking and sanitary purpose the consumption at any point of time should not exceed 150 m3 per day, which means there is scope in this area to reduce the consumption by about 350 m3 per day i.e. 127750 m3 per annum.
2. The maximum number of people at any point of time in the town ship (colony) including the employees and outsiders (contracted workers) is not likely to exceed 2500. Taking Indian standard of water consumption at the rate of 100 litres per person/day, the consumption is not likely to exceed 250 m3/day. As per the international standard about 150 litres of water is consumed per person per day. Applying the mean standard of 120 litres per person per day, the water consumption should not exceed 300 m3/day. However, from the record made available to us, it appears that the daily consumption is in excess of 600 m3/day and this it self offers scope to reduce the consumption by about 300 m3/day i.e. 109,500 m3/annum.
1. Total water cost saving potential identified is Rs 72.6 lakhs/year.
2. The plant has already invested in change of intercooler tubes of Syngas compressor, and has planned for condensate recovery schemes so that stripper operation can be minimized.
Water Cost Saving