ENERGY MANAGEMENT SYSTEM MANUAL CAUSTIC SODA UNIT

Doc. No. IDM/CL2 PLANT/08

ENERGY REVIEW
Page No: 1 of 15

1)CHLORINE PLANT :

(a) LIQUID CHLORINE PLANT:

The hot chlorine from cells contains solid impurities such as brine mists etc. which are removed
in chlorine cooler and mist eliminator. The cooled chlorine is further cooled with chilled water
in heat exchanger, dried in sulphuric acid driers and then sent to liquefier through a filter via
chlorine compressor and mist eliminator.
The liquid chlorine from liquefier goes to the storage tank from where it is transferred to Cl 2
cylinder through dehumidified air padding.
(b)HYDROCHLORIC ACID PLANT:

In hydrochloric acid section the hydrogen gas is burnt with chlorine to get Hydrogen chloride
gas which is absorbed in a week acid in a falling film absorber to get 33 % Hydrochloric acid
solutions. The unabsorbed gases from the absorber go to recovery column where any left over
Hydrochloric acid vapour gets removed with feed D.M.water to from weak acid which then
goes to the absorber.
(c) HYPOCHLORITE PLANT:
In the hypochlorite section chlorine gases are utilized from :

 Uncondensed gases from liquefier.

 Exhaust gases from degasifier of both plant (Mercury cell + membrane cell).
 Sniff gases from chlorine receivers, chlorine storage tanks and chlorine toners and
 Gases from cells as per requirement

These gases are absorbed in a concrete tower with milk of lime which is received from M/S
Orient Paper Mills, Amlai. The chlorine gas, reacts with milk of lime forming calcium
hypochlorite. Unabsorbed gases of Ist Tower goes to IInd Hypo Tower to absorbed remaining
chlorine gas if any.
Always some excess lime is maintained in the both tower so that the gases leaving the
absorption tower do not contain any chlorine. The Hypo Chlorite from tower goes to hypo
settler where sludge gets settle and drained out and clear hypo liquor goes to the tank from
where it is pumped to M/S Orient Paper Mills, Amlai.

ISSUE/REV. NO DATE ISSUED BY- HOD APPROVED BY –ENGG. HEAD

04/01 01.04.2018
 ENERGY MANAGEMENT SYSTEM MANUAL CAUSTIC SODA UNIT
Doc. No. IDM/CL2 PLANT/08
ENERGY REVIEW
Page No: 2 of 15

2)LIQUID CHLORINE PLANT PROCESS

Cooling and Drying-The Cl2 gas of IEM plant is sent to washing tower. The chlorine gas is cooled in
secondary heat exchanger. CL2 gas from secondary cooler is passed through the drying tower. In
this section the CL2 gas comes in contact with circulating sulfuric acid. Most of the moisture in the
CL2 gas gets absorbed by the acid. The chlorine gas from the top of the drying tower is taken to filter
anf any carry over sulfuric acid is eliminated in the filter.

98% sulphuric acid is pumped to the drying tower by means of metering pump. The dry chlorine gas
from drying tower is compressed to 3.5Kg/cm2 by means of chlorine compressor. The acid and has
gets separated in separator. The heat of compression from the acid is removed by means of cooling
in heat exchanger.

Compression-The compressed chlorine gas after the separator still contains sulfuric acid which is
removed by mist eliminators. The compressed CL2 gas goes to liquefier. Sulfuric acid in CL2
compressors and coolers is of 98% concentration. Any moisture that remains in cL2 gas after drying
tower is absorbed by acid in compressors.

Liquification-The liquefier is horizontal type shell & tube condenser in which the refrigerant gas
Freon R-22 evaporates on the shell side while cL2 gas condenses on tube side. The chlorine gas
pressure in the liquefaction system is controlled by sniff gas control valve. Same pressure that is in
the chlorine liquefier is also maintained in the chlorine receiving tank by pressure equalizing line that
interconnects two vessels. To prevent the gas flow from the liquefier to liquid receiving tank a liquid
chlorine seal is given in the line. The liquefied chlorine collecting at the bottom of the liquefier is piped
to the chlorine receiving tank.

Liquid Cl2 Filling Section- Liquid Chlorine is stored in storage tanks( 4 nos of capacity 50Ton each)
and receivers(2 nos of capacity 16 Ton each). Providing dehumidified air padding at 10Kg/cm2 to the
filled storage tank liquid chlorine is transferred Tonner filling section and OPM.
Cl2 tonners after unloaded by hoists are passed through hydraulic stretch test. If the tonner is due for
testing it is sent to tonner washing area where the tonner is sniffed to remove residual chlorine gas.
Then washed, tested and weighted. If the tonner passes the test then after drying & vacuum that
tonner is filled at filling point. After filling the tonners are stored in the yard for at least 24Hrs for safety
purpose, checked with ammonia for leakage before loading to trucks.

ISSUE/REV. NO DATE ISSUED BY- HOD APPROVED BY –ENGG. HEAD

04/01 01.04.2018
 ENERGY MANAGEMENT SYSTEM MANUAL CAUSTIC SODA UNIT
Doc. No. IDM/CL2 PLANT/08
ENERGY REVIEW
Page No: 3 of 15

3)PROCESS FLOW DIAGRAM

ISSUE/REV. NO DATE ISSUED BY- HOD APPROVED BY –ENGG. HEAD

04/01 01.04.2018
 ENERGY MANAGEMENT SYSTEM MANUAL CAUSTIC SODA UNIT
Doc. No. IDM/CL2 PLANT/08
ENERGY REVIEW
Page No: 4 of 15

ISSUE/REV. NO DATE ISSUED BY- HOD APPROVED BY –ENGG. HEAD

04/01 01.04.2018
 ENERGY MANAGEMENT SYSTEM MANUAL CAUSTIC SODA UNIT
Doc. No. IDM/CL2 PLANT/08
ENERGY REVIEW
Page No: 5 of 15

1)ENERGY USE

The Energy Sources of CL2 Plant are:-

1)Electricity-
The Electricity used for running of all process motors in this area is called “Cl2 Auxiliary Power”.
CL2 Auxiliary Power is fed through CL2 Plant MCCS and facilitated to individual motors through
starter feeders.

Electricity is also used for lighting in plant areas.

2)METHODS OF MEASUREMENT

The “CL2 Auxiliary Power” is measured by respective 3Phase Energy Meters provided in CL2 Plant
MCC.

3)ENERGY CONSUMPTION SHARE AND SIGNIFICANT ENERGY USE

In order to compare overall data, values of consumption for last 03 Years is collected and analyzed.

Sr. PARAMETERS UNIT 2016-17 2017-18 2018-19

No

a CL2 Auxiliary Power KWh 2614993 2387149 2404654

Consumption
b Liquid CL2 Production MT 19037.00 15590.00 15945.00
c CL2 Auxiliary Power Kwh/MT 137.36 153.12 150.80
Consumption
per Ton of Liquid CL2
Production.
d Cl2 Auxiliary Power MKcal 8875.286 8101.983 8161.395
(aX3394Kcal/KWh)/1000000
e Cl2 Auxiliary Power toe 887.5286 810.1983 816.139
Consumption (d/10)
f Net SEC Lye basis toe/MT 0.0466 0.0519 0.0511

The substantial energy use is the CL2 Auxiliary Power as no other energy source plays a vital role
in this area.

ISSUE/REV. NO DATE ISSUED BY- HOD APPROVED BY –ENGG. HEAD

04/01 01.04.2018
 ENERGY MANAGEMENT SYSTEM MANUAL CAUSTIC SODA UNIT
Doc. No. IDM/CL2 PLANT/08
ENERGY REVIEW
Page No: 6 of 15

4)ENERGY PERFORMANCE INDICATORS TRENDS

The trend of EnPI: IEM AC ELECTROLYSIS POWER PER TON OF CAUSTIC PRODUCTION KWh/MT for
Last 03 Years is depicted below.

ISSUE/REV. NO DATE ISSUED BY- HOD APPROVED BY –ENGG. HEAD

04/01 01.04.2018
 ENERGY MANAGEMENT SYSTEM MANUAL CAUSTIC SODA UNIT
Doc. No. IDM/CL2 PLANT/08
ENERGY REVIEW
Page No: 7 of 15

5)VARIABLES AFFECTING SIGNIFICANT ENERGY USE

The variables affecting consumption of significant energy use of CL2 Auxiliary Power are:-

1)Plant Loading and Load of IEM Plant – The load of IEM plant plays a vital role. If load is less
than 50KA the CL2 Compressor A (170HP) is run and above 50KA load to handle CL2 gas above 60
Ton CL2 Compressor D (225HP) is required to run.

2)Operation of 30TPD & 20TPD HCL Plant- If 30TPD HCL Plant is OFF 2 nos of CL2 compressors
and 2Nos of Freon Compressors are required. With starting of 30TPD HCL Plant one of the Freon
compressor and CL2 Compressors are stopped.

6)ENERGY PERFORMANCE INDICATORS

Relevant Energy Performance Indicators regarding Energy Usage are as following:-

1) CL2 AUXILIARY POWER PER TON OF LIQUID CL2 PRODUCTION

It is defined as the ratio of daily/monthly electricity consumption for CL2 Auxiliary Power to total
production in MT expressed as KWh/MT or toe/MT

7)METHODOLOGY FOR FIXING BASELINE SEC

The methodology for setting baseline SEC has been developed on the basis of SEC Regression
Method considering last 03 Years energy use patterns, analysis of production trends and capacity
utilization, analysis of energy scenario and various factors affecting SEC for CL2 Auxiliary Power..

BASELINE SEC OF CL2 AUXILIARY POWER PER TON OF CL2 PRODUCTION.

CL2 Plant Energy Consumption and Actual Production of Last 03 Years ( 2016-17, 2017-18 and
2018-19 ) are plotted on graph taking Production on X axis and Energy Consumption of Y axis.
The Equation of the graph is obtained and the calculated energy is tabulated on its basis. The
difference of Calculated and Actual Energy and CUSUM is prepared to analyze gain or loss.

ISSUE/REV. NO DATE ISSUED BY- HOD APPROVED BY –ENGG. HEAD

04/01 01.04.2018
 ENERGY MANAGEMENT SYSTEM MANUAL CAUSTIC SODA UNIT
Doc. No. IDM/CL2 PLANT/08
ENERGY REVIEW
Page No: 8 of 15

YEAR MONTH ACTUAL Eact ACTUAL Ecal Eact-Ecal CUSUM

PROD ACTUAL KWH/TON ADJUSTED TO KWh
AUXILIARY BASELINE KWH
POWER Y=91.94X+75556
KWh
APR 1613.00 229159 142 226011 3148 3148
MAY 940.00 146246 156 160474 -14228 -11080
JUN 1792.00 269972 151 243442 26530 15450
JUL 1673.00 220932 132 231854 -10922 4528
AUG 1739.00 234042 135 238281 -4239 289
SEP 1446.00 227175 157 209748 17427 17716
2016-17
OCT 1507.00 216797 144 215689 1108 18824
NOV 1866.00 233511 125 250648 -17137 1687
DEC 1743.00 210150 121 238670 -28520 -26833
JAN 1716.00 217273 127 236041 -18768 -45601
FEB 1384.00 187111 135 203711 -16600 -62201
MAR 1618.00 222625 138 226498 -3873 -66074
TOTAL 19037.00 2614993 137 2681067 -66074  
APR 1270.00 193570 152 192610 960 960
MAY 1315.00 198895 151 196992 1903 2864
JUN 1196.00 181453 152 185403 -3950 -1087
JUL 1410.00 219525 156 206243 13282 12195
AUG 1241.00 205978 166 189786 16192 28388
SEP 1277.00 216230 169 193291 22939 51327
2017-18
OCT 1371.00 220023 160 202445 17578 68905
NOV 1333.00 214614 161 198745 15869 84774
DEC 1353.00 194467 144 200692 -6225 78549
JAN 1415.00 194578 138 206730 -12152 66397
FEB 1090.00 158557 145 175081 -16524 49873
MAR 1319.00 189259 143 197381 -8122 41751
TOTAL 15590.00 2387149 153 2345398 41751  

ISSUE/REV. NO DATE ISSUED BY- HOD APPROVED BY –ENGG. HEAD

04/01 01.04.2018

ENERGY MANAGEMENT SYSTEM MANUAL CAUSTIC SODA UNIT

ENERGY REVIEW Doc. No. IDM/CL2 PLANT/08
 Page No: 9 of 15

APR 1333.00 185928 139 198745 -12817 -12817

MAY 1291.00 189730 147 194655 -4925 -17741
JUN 1085.00 165750 153 174594 -8844 -26585
JUL 1398.00 222683 159 205074 17609 -8977
AUG 1509.00 240297 159 215883 24414 15437
SEP 1382.00 222717 161 203516 19201 34638
2018-19
OCT 1369.00 191190 140 202250 -11060 23578
NOV 1397.00 195370 140 204977 -9607 13971
DEC 1258.00 181085 144 191441 -10356 3615
JAN 1268.00 188879 149 192415 -3536 79
FEB 1193.00 183985 154 185111 -1126 -1048
MAR 1462.00 237040 162 211307 25733 24686
TOTAL 15945.00 2404654 151 2379968 24686  

ISSUE/REV. NO DATE ISSUED BY- HOD APPROVED BY –ENGG. HEAD

04/01 01.04.2018

ENERGY MANAGEMENT SYSTEM MANUAL CAUSTIC SODA UNIT

Doc. No. IDM/CL2 PLANT/08
ENERGY REVIEW
Page No: 10 of 15
The Equation obtained is Y=97.38X+68937
Where X= Production, Y= Calculated Energy Consumption.

Now the Intercept of this line is set to Zero to get the graph in form Y=mX=145.4X

ISSUE/REV. NO DATE ISSUED BY- HOD APPROVED BY –ENGG. HEAD

04/01 01.04.2018

ENERGY MANAGEMENT SYSTEM MANUAL CAUSTIC SODA UNIT

Doc. No. IDM/CL2 PLANT/08
ENERGY REVIEW
Page No: 11 of 15
CL2 Plant Auxiliary Power Baseline SEC for 2019-20 145.4 KWh/MT.
.

CL2 Plant Auxiliary Power Targeted SEC for 2019-20 145.0 KWh/MT.

ISSUE/REV. NO DATE ISSUED BY- HOD APPROVED BY –ENGG. HEAD

04/01 01.04.2018

ENERGY MANAGEMENT SYSTEM MANUAL CAUSTIC SODA UNIT

ENERGY REVIEW Doc. No. IDM/CL2 PLANT/08
 Page No: 12 of 15

HCL PLANT
In HCl Plant dilute 30-32% Hydrochloric Acid is produced . The H2 has is burnt with CL2 gas to get
hydrogen chloride gas. Hydrogen Chloride gas is then absorbed in falling film absorber with dilute
acid to get 30-32% acid solution. Unabsorbed gas goes to recovery column or tail tower where any
left over hydraulic acid vapours gets removed with DM water to form weak acid that then goes to
absorber. The Hydrochloric Acid is stored in FRP Storage tanks. The HCL is loaded in HCL tanker for
dispatch. HCL is also transferred to IEM plant.

The Energy Sources of HCL Plant are:-

1)ENERGY USE

1)Electricity- The Electricity is used in HCL Plant for running of process motors in this area called
“HCL Auxiliary Power”. HCL Plant Power is fed through MCC to individual motors through starter
feeders. Electricity is also used for lighting in plant.

H2 Gas is used in Production of HCL and not a source of energy

2)METHODS OF MEASUREMENT

The “HCL Auxiliary Power” is measured by respective 3Phase Energy Meters provided in HYPO
HCL Plant MCC.

3)ENERGY CONSUMPTION SHARE AND SIGNIFICANT ENERGY USE

In order to compare overall data, values of consumption for last 03 Years is collected and analyzed.

Sr.No PARAMETERS UNIT 2016-17 2017-18 2018-19

a HCL Auxiliary Power KWh 39637.0 66510.0 68288.0

Consumption

b HCL Production MT 33396.00 50419.00 51867.00

c HCL Auxiliary Power Kwh/MT 1.1868 1.319 1.316
Consumption
per Ton of Liquid CL2
Production.
d HCL Auxiliary Power MKcal 134.527 225.734 231.769
(aX3394Kcal/KWh)/1000000
e Cl2 Auxiliary Power toe 13.4527 22.5734 23.176
Consumption (d/10)
f Net SEC Lye basis toe/MT 0.00040 0.000447 0.000446

ISSUE/REV. NO DATE ISSUED BY- HOD APPROVED BY –ENGG. HEAD

04/01 01.04.2018

ENERGY MANAGEMENT SYSTEM MANUAL CAUSTIC SODA UNIT

ENERGY REVIEW Doc. No. IDM/CL2 PLANT/08
 Page No: 13 of 15

4)ENERGY PERFORMANCE INDICATORS

Relevant Energy Performance Indicators regarding Energy Usage are as following:-

HCL AUXILIARY POWER TON OF HCL PRODUCTION

It is defined as the ratio of daily/monthly auxiliary Power used in KWh to total HCL production in MT.

5METHODOLOGY FOR FIXING BASELINE SEC

The methodology for setting baseline SEC has been developed on the basis of SEC Regression
Method considering last 03 Years energy use patterns, analysis of production trends and capacity
utilization, analysis of energy scenario and various factors affecting SEC for CL2 Auxiliary Power..

BASELINE SEC OF HCL AUXILIARY POWER PER TON OF HCL PRODUCTION.

CL2 Plant Energy Consumption and Actual Production of Last 01 Years and 2016-17 are plotted on
graph taking Production on X axis and Energy Consumption of Y axis.

The Equation of the graph is obtained and the calculated energy is tablated on its basis. The
difference of Calculated and Actual Energy and CUSUM is prepared to analyze gain or loss.

YEAR MONTH ACTUAL Eact ACTUAL Ecal Eact-Ecal CUSUM

PROD ACTUAL KWH/TON ADJUSTED TO KWh
AUXILIARY BASELINE KWH
POWER Y=0.502X+3399
KWh
APR 3721 5476 1.47 1531 3945 3945
MAY 3909 6481 1.66 1437 5044 8989
JUN 2662 4850 1.82 2063 2787 11777
JUL 4214 6533 1.55 1284 5249 17026
AUG 4155 6093 1.47 1313 4780 21806
SEP 4506 6181 1.37 1137 5044 26850
2017- OCT 4404 5837 1.33 1188 4649 31499
18 NOV 4512 5268 1.17 1134 4134 35633
DEC 4602 4934 1.07 1089 3845 39478
JAN 4734 4780 1.01 1023 3757 43235
FEB 4070 4535 1.11 1356 3179 46414
MAR 4930 5542 1.12 924 4618 51032

TOTAL 50419.00 66510 1.32 15478 51032

ISSUE/REV. NO DATE ISSUED BY- HOD APPROVED BY –ENGG. HEAD

04/01 01.04.2018

ENERGY MANAGEMENT SYSTEM MANUAL CAUSTIC SODA UNIT

Doc. No. IDM/CL2 PLANT/08
ENERGY REVIEW
Page No: 14 of 15
YEAR MONTH ACTUAL Eact ACTUAL Ecal Eact-Ecal CUSUM
PROD ACTUAL KWH/TON ADJUSTED TO KWh
AUXILIARY BASELINE KWH
POWER Y=0.502X+3399
KWh
APR 4425.00 6216 152 1178 5038 5038
MAY 3595.00 6277 151 1594 4683 9721
JUN 2717.00 4252 152 2035 2217 11938
JUL 5005.00 6943 156 886 6057 17994
AUG 4764.00 6203 166 1007 5196 23190
2018- SEP 4415.00 5773 169 1183 4590 27780
19 OCT 5105.00 6008 160 836 5172 32952
NOV 5012.00 5382 161 883 4499 37451
DEC 4550.00 5193 144 1115 4078 41529
JAN 3982.00 5088 138 1400 3688 45217
FEB 3446.00 4443 145 1669 2774 47991
MAR 4851.00 6510 143 964 5546 53537
TOTAL 51867.00 68288 1.32 14751 53537  

ISSUE/REV. NO DATE ISSUED BY- HOD APPROVED BY –ENGG. HEAD

04/01 01.04.2018
The Equation obtained is Y=0.502X+3399
Where X= Production, Y= Calculated Energy Consumption.

Now the Intercept of this line is set to Zero to get the graph in form Y=mX=1.299X

HCL Plant Auxiliary Power Baseline SEC for 2019-20 1.299 KWh/MT.

HCL Plant Auxiliary Power Targeted SEC for 2019-20 1.297 KWh/MT.

ISSUE/REV. NO DATE ISSUED BY- HOD APPROVED BY –ENGG. HEAD

04/01 01.04.2018