Tata Chemicals has implemented several schemes to save energy across its plants, including the commissioning of a solar photo-voltaic plant
Installation of the Flash Vessel to generate Low Pressure Steam from the HRSG Blow Down:
Tata Chemicals has two Gas Turbine (21 MW at operating condition) along with Heat Recovery Steam Generation (HRSG) units. An HRSG unit consists of a boiler drum, blow down vessel, etc. Earlier, the blow down vessel of the HRSG unit was open, and the heat vapours would escape through the opening. To recover heat, It was decided that a common flash vessel be installed for low pressure steam (LS) generation from HRSG - 1&2 blow down vessels, and the steam generated was connected with the existing LS header.
The blow downrate was 0.985 MTPH with a single GTG+HRU running. With two GTG+HRU running at 50 percent load, the design blow down quantity is 0.493X2 MTPH. We are getting the benefit of almost 11 MT low pressure steam generation per day by flashing of HRSG blow down @ 3-4 Kg/Cm2g.
Installation of Casale trays in Urea Reactor (11-R-1) to improve conversion efficiency and to reduce steam consumption:
Technological developments have led to the development of a new, more efficient tray leading to higher conversion by approximately 1.5-2 % (CO2 conversion) as compared to the existing conventional trays for the urea reactor. Presently 15 Trays are installed inside the urea reactor and all fifteen trays have been replaced with high efficiency Casale trays. This modification helped improve yield conversion of urea and to save energy. We experienced approximately 20kg /MT of medium pressure steam from this modification.
Cleaning ammonia plant primary reformer waste heat recovery coils to improve heat transfer effectiveness
CETEK dry ice cleaning:
CETEK is the US-based executing agency that specialised in cleaning WHRS coils by a method of blasting dry ice. For the first time in India, Tata Chemicals decided to implement this method. Dry ice pellets are blasted on the finned surface with the help of a pressurised air stream. Top layer dirt/contaminants are removed easily due to quick sublimation. It is more effective and lasts longer as compared to conventional hydro-jet cleaning.
Installation of Solar Photovoltaic Cells of 150 KW power rating:
A solar energy-based power generation system will be a robust and clean technology. It will reduce a considerable amount of GHG emissions, and will contribute to a better quality environment for employees and nearby communities.
In order to harness non-polluting renewable energy resources to control greenhouse gas emissions, it has been proposed to set up a 150 kWp grid-connected solar photovoltaic power plant on the rooftop terrace of the electrical sub-station. This will also help to partially meet the load demand of the plant.
The 150 kWp SPV power plant is estimated to afford an annual energy feed of 210 MWh/year considering the efficiency of the solar module as 16%. a capex of Rs2 crore was approved for the installation of the plant. In 2014-15, 50 kWp/100 KWp SPV power plants have been commissioned and its benefits are being reaped.
CII Excellent Energy Efficient Unit Award:
FAI Best Production Performance Award