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TATA CHEMICALS LIMITED Soda Ash Plant, Mithapur (Gujarat) Unit Profile Incorporated in 1939, Tata Chemicals Limited is India’s leading manufacturer of Inorganic Chemicals. It also manufactures fertilizers and food additives. The company has an annual turnover of Rs. 3000 Crores and is a part of Rs. 65,000 Crore ($14.25 billion) Tata Group, India’s foremost business conglomerate. Energy Conservation Commitment, Policy & Organization Set up Energy Conservation Approach at Tata Chemicals Limited and commitment from Top management can be best described by, Energy Scan Situation Management Managem Policy Scan Energy Plan ent Target Envr. & Cost Energy Consumption Analysis Energy Scan Energy Plan How efficient is the equipment? * What is the Energy Policy? How efficient are the processes? * What are the targets? What is the peak sustainable performance? * How can target be reached Where are the performance gaps? * What rare the resources requirement Energy Consumption Analysis Management Scan How much energy is used? * How is the management organized? What are the total system costs? * Are require resources provided? What are the environmental impacts? * Are performances reviewed? * Are people motivated & engaged? In house training program are arranged interval by internal faculty as well as through external faculty, sharing of best practices between intra dept. through knowledge sharing session, communication for ENCON achievement through mails are regular activity at TCL, Mithapur. Energy Conservation Week is celebrated from 14th to 21st of December during which the competitions like Slogan, Drawing, Essay Writing, Quiz etc are arranged for spreading mass awareness. Energy Consumption Unit 2003-04 2004-05 2005-06 Annual Soda Ash Production Mt 754553 781858 810684 Soda Ash Plant – Capacity Utilization % 86% 89% 93% Total Electrical Energy Consumption Lac kWh 3647.84 4036.88 4203.84 Total Thermal Energy Consumption Mkcal 3385392 3424126 3547063 Total Manufacturing Cost Rs. Lacs 32725 41670 40834 Energy cost as % of Manufacturing Cost % 28.67 27.04 30.61 Soda Ash heat energy consumption Mkcal/T 2.951 2.979 2.915 Soda Ash Power Consumption kWh/T 146.52 146.83 157.76 Energy Management Policy: Copy of EMP is attached with this document. Charts Soda Ash production Soda Ash % Capacity Utilization S o d a A s h P r o d u c ti o n , 850000 96.00% % C a p a c ity U tiliz a tio n 92.65% 93.00% 800000 89.36% 90.00% Mt 86.23% 87.00% 750000 84.00% 700000 81.00% 2003-04 2004-05 2005-06 2003-04 2004-05 2005-06 Year Year Soda Ash thermal energy consumption Soda Ash Electrical Energy Consumption T h e r m a l E n e r g y M k c a l/T 3.00 170 E l e c tr i c a l E n e r g y , 2.98 2.979 160 157.76 2.951 2.96 kW h /T 146.52 146.83 2.94 2.915 150 2.92 140 2.90 2.88 130 2003-04 2004-05 2005-06 2003-04 2004-05 2005-06 Year Year Energy Cost at % of Manufacturing Cost Annual Furnace Oil Consumption 40.00% 220 210 200 212.58 210.25 35.00% F . O il, K L 30.61% 190 % C ost 30.00% 28.67% 27.04% 180 170 167.53 25.00% 160 150 20.00% 2003-04 2004-05 2005-06 2003-04 2004-05 2005-06 Year Year ENCON Cell Structure: Vice President - Manufacturing General Manager – Engineering Services Manager – Operational Excellence Asst. Manager – Water Conservation Asst. Manager – Energy Conservation Energy Conservation Achievement: Power Savings Ideas: 1) Optimization of Transformer loading by, Downsizing the transformer Removing the ideal transformer Proper load distribution among the transformers. Total Investment: Rs. 14.35 Lacs Power Saving: 82.6 KW 2) Optimization of pumping operation by removing inefficient pumps and installing the higher capacity high efficiency pumps at Make Up Water Plant. Total Investment: Rs. 6.61 Lacs Power Saving: 29.42 KW 3) Installation of AC Variable Speed Drive in different drives across the plant. Total Investment: Rs. 104 Lacs Power Saving: 473 KW Thermal Savings Ideas: 1) Improvement in PHE effectiveness by schedule cleaning of plates of heat exchanger and thus reduce the 20# Dearator steam consumption at Power Plant Total Investment: Nil Equivalent Coal Consumption reduction: 1050 TPA 2) Arresting the heat leakages by properly insulating the steam lines and development of schedule for checking the surface temp. of steam line and immediately take corrective action for any damage insulation. Total Investment: Rs. 18.21 Equivalent Coal Consumption reduction: 528 TPA 3) Hot Water purging for cooling tower for reducing the heat load on cooling tower. Total Investment: Rs. 12.00 Lacs Equivalent Coal Consumption reduction: 564 TPA Energy Conservation Plans & Targets: Sr. Energy Conservation Measure Investment, Savings, Completion No. Rs Lacs Rs. Lacs Year 1 To provide glass wool separable type insulation for 0.00 1.10 2006-07 Free ammonia still tower, WLDS tower & Wet Calciner joints. 2 Replacing existing Low efficiency Primary Air Fan 1.35 0.62 2006-07 with Higher efficiency Fan 3 Reduce power consumption in lighting loads by 8.41 3.43 2006-07 installing energy saving device for lighting loads. 4 To change Electrolyser membrane from Nafion 0.00 16.95 2006-07 966TX to Flamion F-8031 for power saving. 5 To collect MUW FBD condensate and then flash it 41.47 14.57 2006-07 to 20# psig to get steam 6 To provide steam trap to recover condensate from 5.44 2.68 2006-07 20#, 50# & 120# steam line 7 Recovery of water at the time of softening tower 1.47 0.06 2006-07 cleaning at Water Treatment Plant 8 Recovery of power plant's all traps' condensate and 3.45 0.20 2006-07 atlas copco compressors' drain water to MUW bad condensate tank. 9 Water recovery from Bromine Glass tower steam 0.40 0.12 2006-07 condensate 10 Installation of push cock at works & Public places of 0.88 0.59 2006-07 town to optimize Drinking water usage 11 To stop overflow of the DA water tank for Khosla 1.93 0.16 2006-07 Compressor 12 To enhance the efficiency of Atlas Copco Air 71.00 25.72 2006-07 Compressor No. 1 to 4. 13 Pre-heating of brine with condensate of calendria -1 6.31 22.88 2006-07 in NBE plant. 14 Installation of Electronic Choke in place on 26.25 11.19 2006-07 Conventional chokes 15 Installation of Variable Frequency Drive for Chlorine 11.17 3.51 2006-07 & Hypo Blower for reduction in Power Consumption. Environment & Safety: Safety In Tata Chemicals Ltd's (TCL) Mithapur plant, safety is accorded the highest priority and commitment from the top management. A good safety and occupational health programme is in place to ensure the safety of employees, and the equipment / machinery in Tata Chemicals' multi-product facility at Mithapur. The factory is ISO:14001-certified. In addition to this, OHSAS - 18001 standards have been achieved, so as to strengthen the occupational health and safety systems. Simultaneously, for salt-handling, the HACCP (Hazard Analysis and Critical Control Point) certification is also being acted on. Some of the significant initiatives that are undertaken in recent time are Five start rating from British Safety Council, Participation in Responsible Care initiative, Regular internal and extern safety audits and implementation of findings, Training to employees and contractor worker and awareness session. Environment: Among the largest and oldest chemical plants in India, the chemicals division of Tata Chemicals Ltd (TCL) at Mithapur is a model complex, which strives to continuously improve the quality of life of its employees and the community it serves. The township is ISO 14001-certified. Tata Chemicals Limited, Mithapur has recently won the “Green Governance Award” 2005 for its project of “Conservation of Whale Shark”. The Green Governance Awards have been instituted by Bombay Natural History Society (BNHS) in order to provide impetus to sustainable development and to encourage environmental protection initiatives. The purpose of the award is to recognize and appreciate an organization’s efforts beyond meeting statutory compliance for protection and conservation of the environment.
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