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Energy Conservation through Instrumentation in CHLOR-ALKALI INDUSTRY ( BEE -Workshop,

Energy Conservation through Instrumentation in CHLOR-ALKALI INDUSTRY ( BEE -Workshop, Mumbai ,11Sept.’08 ). P.N.Parikh. Certified Energy Auditor -2006 Instrumentation Chief at GACL- Gujarat Alkalies and Chemicals Limited

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Energy Conservation through Instrumentation in CHLOR-ALKALI INDUSTRY ( BEE -Workshop,

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  1. Energy Conservationthrough Instrumentation in CHLOR-ALKALI INDUSTRY ( BEE -Workshop, Mumbai ,11Sept.’08 )

  2. P.N.Parikh • Certified Energy Auditor -2006 • Instrumentation Chief at GACL- Gujarat Alkalies and Chemicals Limited • Chief Engineer: Chlor-Alkali plant at Saudi-Arabia • Asst. Professor(Instrumentation) at LDCE, A' bad • Engineering Qualifications: BE(electrical) DME(mechanical) DERE(electronics) Total experience:33 yrs.industrial+ 5yrs.Acadamic

  3. Five areas of High Saving Potential in Chlor-Alkali plant • Electrolysers / Membrane or Mercury Cells in Cell – House. • Compressors:Chlorine, Air, Refrigeration • Pumps: Cooling water; Brine to cells, Anolyte, • Rectiformers: Diode / Thyristor Thermal: • Caustic Evaporation / Concentration

  4. Energy Conservation throughInstrumentation in Chlor-Alkali Industry • Instrumentation trends in Chlor-Alkali sector 1970-80:Pneumatic 1981-93:Electonic-Single loop controllers 1993-2000:DCS/PLC • 1993-94:DCS introduced in GACL while converting the balance mercury plant to membrane cell plant (MC-II: Second Mercury to Membrane Conversion)

  5. DCS- a tool to monitor Energy in Manufacturing Processes • Current monitoring of high power motors on DCS can give better analytic capability for : Power and equipment performance of : • Chorine Compressors • Refrigeration Compressors • Air- Compressors • Cooling tower water pumps • Brine & Caustic pumps • Vortex meter / Mass flow meter for : NG,Steam,Hydrogen,Air

  6. Energy –Electrical & Thermal • Electrolysis- Mercury/Membrane Cells • Compressors- (Chlorine+Refrigeration+Air) • Pumps- -Brine to cells -Anolyte Brine to saturators -Cooling water circulation pumps Thermal –Energy: • Caustic Concentration Unit : Steam / NG / Hydrogen • (Steam / NG or Hydrogen burning )

  7. VFDs Application in Chlor-alkali Industry • Areas identification(Using DCS / otherwise) • Control Valve opening in the range of 30-50 % for pressure, level, flow controls can be easily considered for VFD applications • Caution: Old motors’ name-plate frequency has normally limit of +/_ of 5 % and may not be suitable for VFD power at low speeds- Limit :47.5 Hz • Large motors with throttled operation of Discharge –valve can also be considered for VFD application on water circuits

  8. Electrolysis Power monitoring • Cell –Voltage moni.& control system: Technically sound companies from Japan and Germany are in the field to offer voltage monitoring system for cell- elements of the electrolysers • This data helps operators to know the condition of membranes / anode-cathode coating and decide about remembraning techno-economically.

  9. Monitoring of Electrical Substation Power on DCS • Current transducers and potential free contacts from PCC,MCC can be connected to DCS for monitoring of total current, power and power factor on DCS. • Power-factor control can also be engineered through DCS /PLC of the main plant • PLC may also be deployed for sequential and part load application of reciprocating air/ hydrogen compressors to suit the variable load condition of the process.

  10. Energy-overview page on DCS • It is a high time that plant operators should demand Energy Overview page on DCS to know daily status of online energy consumptions and target to optimize the same. • Operational efficiency by DCS/PLC has potential to show quantifiable energy saving by a more competent & experienced operator as he knows when to switch off uncalled for running equipment from Overview page.

  11. Measure(Accurately) to Manage • Density of Caustic (Nucleonic/ Vibrating fork/Conductivity) • Quantity of Chlorine (Mass flow meter / Vortex meter) • Quantity of water (Magnetic flow meter) • Quantity of Steam (Vortex flow meter) • Quantity of Air(Vortex flow meter) • Quantity of Hydrogen (Mass flow meters) • Quantity of DC Power in cells (CVMS) • Quantity Brine/Caustic in Cells-(Magnetic flow meters)

  12. Essential Measurements to manage efficiently Analyzers in Caustic Industries

  13. IMPORTANCE OF DENSITY ? Plant Production is measured by : Total volume produced and density of the product. • Product (TPD) = ( Volume) x (Density) • Power consumption economy is guaranteed by Technology supplier only if Density is maintained between 30~33 % • Density measurement therefore requires accuracy of 0.01 % or better. 10 Ton error @45 m3/hr. rate at density diff.=0.003

  14. Density before & after Caustic Evaporator

  15. Suggested Energy Saving Measures: • Cell voltage monitoring on one cell on trial basis to optimize opra.parameters • Monitor power consumption of all motors of 50 kW or more on DCS with high /low alarms • VFD on cooling water pumps • VFD on Chlorine, Air Compressors • PLC deployment for compressors control • Use liquid pumps in place of Air for Cl2 transfer within complex (Save compr.Air)

  16. Suggested Measures • Use of Energy Efficient Class EF-1 motors only • Optimize motor sizing as per data of power analyser for motors loaded less than 50 %. • Indentify VFDs applicable cases by monitoring trend of Control valves with 30 % or less opening on DCS . • Monitor trend of VFD’s Amps, kWhs, Hz on DCS • Monitor steam -thermal energy by Vortex flow meters

  17. Suggested Measures • DCS deployment for substation / MCC power /status monitoring • DCS to be configured for Energy –Overview page with dynamic data & alarms functions • Deploy magnetic flow meters, vortex flow meters, mass flow meters for accurate & reliable quantity measurements • Be ready to deploy RFID technology for Chlorine tonners monitoring with active /passive devices with in complex may save transportation cost.

  18. Question – Answer Session Extended help for future query unanswered questions: Contact: E-mail : 1.pnparik@gmail.com 2.pnparikh1@gmail.com Mobile: 99 79 86 1213

  19. Sincere Thanks PN Parikh

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