Energy Conservation Study At UNICHEM LAB, GHAZIABAD

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ENERGY CONSERVATION STUDY REPORT (BOILER HOUSE & STEAM SYSTEM) AT UNICHEM LABORATORIES LTD. LOCATION: C-31 & 32, INDUSTRIAL AREA MEERUT ROAD GHAZIABAD-201003(U.P)

PERSONS CONTACTED: MR. D.B.RAY (MANAGER- ENGINEERING)

STUDY DONE BY : DEBENDU NAG(FORBES MARSHALL)

SUBMITTED BY : FORBES MARSHALL (P) LIMITED, PB NO. 29, PUNE - MUMBAI ROAD, KASARWADI, PUNE 411 034. TEL. 0091-20-39858555 FAX 0091-20-27147379 Email: dnag@forbesmarshall.com

Forbes Marshall Pvt Ltd Pune__________________________________________

Energy Conservation Study At UNICHEM LAB, GHAZIABAD

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REF : DLI/DN/UCLL/1407 DATE:- JULY 14TH, 2011 UNICHEM LABORATORIES LTD. C-31&32, INDUSTRIAL AREA MEERUT ROAD GHAZIABAD KIND ATTN: Mr.D.B.RAY (MANAGER- ENGINEERING) Dear Sir, Subject: ASSURED SAVINGS OF 19 LAKHS!!!! AND RECOVERY OF VALUABLE CONDENSATE We sincerely thank you for the kind courtesy extended to Mr. Debendu Nag while he visited your plant on 20TH JUNE 11 for Energy Conservation from Steam Generation and had the subsequent discussion on the subject matter in details. Energy conservation today is no longer an option with the increasing scarcity of natural resources and spiralling costs of energy, energy conservation today is an absolute necessity to sustain any business. YOU CAN SAVE A TOTAL OF RS. 19 LACS / ANNUM WITH JMN BOILER AND SPIRAX INSTALLATION, WITH A PAYBACK PERIOD OF ABOUT 20 MONTHS Your present annual fuel bill is- Rs. 91 (Rs. lakhs) Savings Expected: Rs. 19- (Rs. Lakhs ). We at the Forbes Marshall Group are committed to the cause of Energy conservation and the association of Spirax Marshall with the various engineering industries is more than 60 years old. Spirax Marshall has technical and financial partnership with Spirax Sarco Limited, U.K. and is the Flagship Company of the Forbes Marshall group. If at any moment of time you have any doubt, please feel free to ask. Thanking you, For Spirax Marshall Pvt. Ltd. Debendu Nag Forbes Marshall Delhi Steam Engineering Group 9910481608 dnag@forbesmarshall.com

Forbes Marshall Pvt Ltd Pune__________________________________________

Energy Conservation Study At UNICHEM LAB, GHAZIABAD

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EXECUTIVE SUMMARY We thank you for the confidence placed in us for suggesting measures of steam and fuel efficiency improvement at your plant. There is a significant scope for improvement both tangible and intangible, tangible being reduction in fuel bill, improvement in productivity and intangibles like reduction of downtime, maintenance costs etc. The areas of study were, y Boiler house y Steam distribution y Steam Utilisation y Condensate Recovery This study report finds tremendous savings potential of 19 L that exists at your plant The major factors influencing the savings are: 1. Steam generation methodology: The existing Coil type boiler is generating very poor quality of steam. Also they are unable to cater to the fluctuating steam demand of the company. If the same are replaced by Shell type Fire tube boiler, the plant steam demand would drastically come down due to improved steam quality. 2. Steam Distribution: Avoiding leakages at valves, propers sizing of steam lines, proper selection and installation of pressure reducing stations at proper location plays important role in saving steam quantity. 3. Steam Utilisation: Analyse the process problems, such as steam starvation, long batch timing, inefficient heating. To give suggestion to improve current steam system to ensure hassle free production. 4. Condensate Recovery: Condensate is recovered from the plant and fed into the Feed water tank. But when the temperature of the Feed Water rises above 60Deg C, the condensate is drained. This is a waste of condensate as well as the energy contained in the steam.

We would be pleased to discuss these findings with you and work with you for implementation of the same and towards achieving the projected savings.

Forbes Marshall Pvt Ltd Pune__________________________________________

Energy Conservation Study At UNICHEM LAB, GHAZIABAD

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DETAILED REPORT With reference to the visit to your plant, the following observations were made of your steam system:-

BOILER HOUSE 1) Boiler:- The existing boilers at your plant are Coil type boilers of the capacity of 850Kg/hr(2 nos). Of them both are required to be run when the plant is on full load condition. Recommendation:- It is recommended to replace the Coil type boilers by Shell type boilers. In shell type boilers, the steam produced is 98.5% dry. Also steam starvation is avoided as no water is wasted as hot water. 2) Boiler blowdown: - blowdown is done at breaks as routine practice. 3) Feed water tank: - the feed water tank is of 5000 Litres, in which 4000 Litres level is maintained. The temperature of Feed water fed in the boiler is maintained at 60 Deg C. The chief reason is that the boiler chamber is hot. If water at 90 Deg C Celsius, is passed through economiser which raises the temperature to 100 Deg C, it would form steam in the coil itself, thereby rupturing the coils of the boiler. Subsequently, more amount of fuel is required to heat the water from 60Deg C to 150Deg C. This results in increase in the fuel bill. 4) Level Controllers on Feed Water tank: - level controller is installed on the feed water tank. Level controllers are used in Feed water tanks to measure the amount of water present in the tank. There must a minimum level of water in the feed water tank to prevent the boilers from running dry.

5) Steam Flow Meter:- The Steam Flow Meter is present to accurately measure the amount of steam flow. The steam flow meter is a vortex type flow meter which accurately senses and shows the flow of steam. The steam pressure rarely remains constant. With varying pressure the mass flow rate also varies proportionately. Hence the vortex steam meter that you procure should have on-line density compensation to give you accurate readings.

Forbes Marshall Pvt Ltd Pune__________________________________________

Energy Conservation Study At UNICHEM LAB, GHAZIABAD

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STEAM DISTRIBUTION

1) Steam Header:- The header of the steam boiler is 20NB in dia. There is a pressure of

8Kg/cm^2 at the header. TD trap is installed at the header to remove the condensate from the Header. Moisture separator is provided just after the boiler to drain out the excess amount of water to ensure dry steam to the process.
2) Pressure reduction: - From the header a single line goes into the plant. The Pressure

reducing station is installed on this line. The pressure is reduced from 8kg/cm^2 to 5kg/cm^2. After the pressure reducing station, vortex type steam flow meter is installed to accurately measure the flow of steam. STEAM UTILISATION 6) Traps: - The traps installed in your process are Ball Float traps(BFT) . This is the correct selection of traps. a) The discharge of condensate in BFT is continuous resulting in proper heating of the equipment, thereby reducing batch timings. b) Ball float traps can handle large amount of condensate compared to Thermodynamic traps. CONDENSATE RECOVERY 1) Flash Steam:- Flash vessel is installed at your plant. Condensate is discharged through steam traps from a higher to a lower pressure. As a result of this drop in pressure, some of the Condensate will then re-evaporate, and is referred to as flash steam. The proportion that will flash off differs according to the level of pressure reduction between the steam and Condensate sides of the system, but a figure of 10-15% by mass is typical. About half of the energy mentioned above (i.e. 12.5% of the total energy supplied) could be lost through flash steam. Flash Steam Recovery is therefore an essential part of achieving an energy efficient system. 2) Condensate recovery Condensate is nothing but DM quality water free from TDS. This can be directly fed into the feed water tank to save water costs. Also when condensate leaves the steam trap it has approximately 20% of the original heat energy contained within the steam. Recovering and returning this valuable energy source saves : Heat energy - saving fuel Expensive water treatment chemicals High feedwater make-up costs At your plant The Spirax Pressure powered pump is installed. But the condensate is not completely returned to the Feed water tank. Once the temperature of 60 Deg C has been attained, the condensate is drained. Also flash steam is fed into the feed water tank.

Forbes Marshall Pvt Ltd Pune__________________________________________

Energy Conservation Study At UNICHEM LAB, GHAZIABAD

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3) De- Areator Head: - There is de-aerator head present at your feed water tank. If the makeup water and flashing condensate are fed to the tank above the water surface, flash steam with all its heat is lost to atmosphere. This results in feed water temperature colder than expected. The De-aerator head combined with Spirax steam injection system ensures quite but vigorous mixing of steam and feed water to reduce dissolved oxygen content to approx 2ppm. This action reduces the need for oxygen scavenging chemicals. The temperature of the feed water is maintained at a high steady level for smooth boiler operation.

Fuel consumption and production records:

Average Fuel Consumption per day per boiler(on full load condition) = 350 lts Average fuel consumption per day(both boilers) = 700 lts Price of fuel/litre = Rs. 37.5 Number of working days = 312days Annual Fuel Bill = 700 x 37.5 x 312 = Rs. 81,90,000 Forbes Marshall Pvt Ltd Pune__________________________________________ 6

Energy Conservation Study At UNICHEM LAB, GHAZIABAD

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BOILER HOUSE 1.1 Study Boiler house (details and findings) Sr. Description Boiler No. 1 Boiler No. 2 Boiler No. 3 No. Boiler Data B-1 B-2 B-3 1 Make Revomax plus Revomax plus 2 Year of Installation 2007 2007 3 Capacity, (Kg/hr) 850 850 4 Design Pressure, (Kg/cm2(g) 10.34 10.34 5 OperatingPressure,(Kg/cm2(g) 8 8 6 Fuel used HSD 7 Stack temperature 250Deg C 250Deg C 8 O2 % in stack 9 CO2% in stack 10 Boiler efficiency(NCV) (Rated) 80 % 80% 11 Feed Water Temperature( C) 60 Deg C 12 Average dryness fraction 65% (Average from Running Pattern) 13 Average steam load & Steam load is nearly constant Timings in a day 14 Seasoned steam demand Plant running is not seasonal ton/day 15 Price of Fuel. (Rs. / Liter) Rs.37.50 16 Fuel liters/day average 700 lts of HSD per day 17 Annual Fuel Bill Lacs Rs. 82 lakhs 18 Working days in a month 26 days 19 Feed Water quality/hardness Soft water/ <5ppm ppm 20 Boiler house area and space available 21 Can relocate boilers Present space is Ok for new boilers 22 Economizer Bypassed no no no 23 Feed water tank capacity (KL) 5000 lts 24 Day oil tank capacity (KL) 1000 lts 25 Bulk oil tank capacity (KL) 20000 lts 26 Chimney height Meters 70mts 27 Condensate recovery (%) 80% (claimed) 28 % of direct steam heating 29 % Condensate sent to ETP? 30 Flash steam recovery Yes possible? (Kg/hr)

Forbes Marshall Pvt Ltd Pune__________________________________________

Energy Conservation Study At UNICHEM LAB, GHAZIABAD

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Total Steam Load = 1200 kg/hr Considering a Diversity Factor of 70% = 840 kg/hr Net Steam Load = 840kg/hr

Considered the future expansion in the pipeline, we would be recommending to go for 2 TPH boiler , F & A at 100 Deg.C. Fuel Consumption By NIBR(Coil Type ) Boiler Operating Parameters 1. Fuel 2. NCV of Fuel 3. Specific Gravity Of HSD 4. Efficiency of Boilers(rated) 5. Generating Pr. Of Boilers 6. Enthalpy of Steam at 8barg 7. Temperature of water at 8barg 8. Temperature of Feed Water 9. Dryness Fraction

HSD 10500 Kcal/kg 0.82 80% 8bar g 661.9Kcal/kg 176 Deg C 40 Deg C 65%

For generating a dry steam load of 840 kg/hr, the coil type boilers will, at 65% dryness fraction, generate steam =840/ 0.65 = 1292 kg/hr Amount of Steam = 840 kg Amount of Hot Water = 1292 kg/hr 840kg/hr = 452 kg Fuel Consumption for generating a 1292kg/hr of steam = 840(661.9-60) + 452(176-60) / 10500 x 0.8 x 0.82 = (505596 + 52432) / 6888 =81 lts/hr HSD consumption per day = 81x 10hrs = 810 lts Price of HSD = rs. 37.5/ lt

Forbes Marshall Pvt Ltd Pune__________________________________________

Energy Conservation Study At UNICHEM LAB, GHAZIABAD

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Running Cost of NIBR boilers = 810 x 37.5 x 312 = Rs. 95 lacs

Proposed Feed water Tank Heat Balance

Capacity of the feed water tank = 3000 lts Level in the tank = 2500lts Steam Load : 1200kg/hr Considering 90% of the condensate is recovered, Amount of recoverable condensate = 1200 x 0.9 = 1080kg/hr Flash steam = (hf at 5 bar hf at 0.5 bar)/ hfg at o.5 = (159 110)/ 532.5 = 10%

Flash quantity @10% of condensate load (1080kg/hr) at 0.5 Bar = 108 kg/hr Resultant feed water temperature, considering all the condensate is used as feed water and the flash steam is vented at the feed water tank- Incase of Shell boiler, all the energy from Flash and condensate is recovered and reused in the boiler. = (972 x 90) + (108 x 610 ) + ( 1300 x 30 ) 2500 = (87480+ 65880 + 39000) / 2500 = 77Deg C

Forbes Marshall Pvt Ltd Pune__________________________________________

Energy Conservation Study At UNICHEM LAB, GHAZIABAD

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Fuel Consumption Of IBR (Shell Type) Boilers Operating Parameters 1. Fuel 2. NCV of Fuel 3. Specific Gravity Of HSD 4. Efficiency of Boilers(rated) 5. Generating Pr. Of Boilers 6. Enthalpy of Steam at 10 barg 7. Temperature of water at 10 barg 8. Temperature of Feed Water 9. Dryness Fraction

HSD 10500 Kcal 0.82 89% 10 bar g 662.9Kcal/kg 181 Deg C 77 Deg C 77 %

Steam Load = 840kg/hr Fuel Consumed to generate 1200 kg/hr of steam =840 (662.9 77) / 10500 x 0.82 x 0.89 = 65 /hr HSD consumption per day = 65 x 10 hrs= 650 lts/day Price of HSD = Rs. 37.5 Running cost of IBR boilers =650 x 37.5 x 312 = Rs.76 lacs

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Energy Conservation Study At UNICHEM LAB, GHAZIABAD

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Savings and Pay Back Matrix

Parameter System Fuel Cost of fuel Rs/Kg Operating hours/Day Operating days/Year Hourly fuel consumption Hourly Operating cost Daily operating cost Yearly operating cost

CASE 1 IBR BOILER HSD 37.5 10 312 65 2,437.5 24,375 76,05,000

CASE 2 NIBR BOILERS HSD 37.5 10 312 81 3,037.5 30,375 94,77,000

Savings Percentage

Annual Savings from Conversion 18,72,000 19%

STILL WOULD YOU LIKE TO RUN COIL TYPE BOILERS ???

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Energy Conservation Study At UNICHEM LAB, GHAZIABAD

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COMPARISION Comparison of IBR Shell Boiler & Non-IBR Coil Boiler

Parameter Design Non-IBR Coil Boiler Once through water tube type boiler Low, typically 75% as found by actual trials None IBR Boiler 3-pass wet back smoke tube boiler As high as 89% on NCV

Overall Steam : Fuel Efficiency Steam space

Steam space available to cater to load fluctuations Can deliver steam at close to constant pressure Large e.g., 750 Kg/hr JNM IBR boiler holds 1342 Kg of water at normal water level Low, Steam quality is unaffected by load variation, because of low steam release velocity Dryness fraction 0.98

Pressure control

Poor

Water holding capacity

Limited, typically 22.5 Kg per coil

Steam release velocity

High, Resulting in poor dryness fraction, typically between 0.65 & 0.75

Susceptibility to poor water

Water tube design requires strict water quality treatment Coils get scaled on the inside and are prone to failure

Smoke tube design can do with medium treatment Smoke tube design, inner surface of tubes can be cleaned easily Periodic tube cleaning is sufficient Adequate water holding capacity enables on-line blowdown & hence TDS control Stage wise inspection at each stage of manufacture and exhaustive testing ensures build standard

Susceptibility to scaling

Maintenance Expenses

Recurring cost of replacing the coils frequently Not possible

On-line Blowdown to maintain TDS

Build Quality of manufacture

No standards, no stage inspection during manufacture, poor testing

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Energy Conservation Study At UNICHEM LAB, GHAZIABAD

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SUCCESS STORIES
COIL VS SHELL: PERFORMANCE AND SAVINGS

Customer

: BAL PHARMA

Bal Pharma has a formulation plant at Shirwal, Pune that produces ear/eye drops and I.V. saline. The plant has a capacity of producing 50,000 bottles (100 ml & 500 ml) and 20,000 bottles of I.V. saline STEAM USING EQUIPMENT Autoclave 2 no. Multicolumn 1 no. Current Average steam load: 500 kg/hr Peak load: 700 kg/hr Parameter Boiler Capacity Make Production Capacity Efficiency (NCV) Fuel Consumption Feed Water Temperature Dryness Fraction Unit Kg/hr COIL TYPE 3 x 400 + 600 kg/hr Thermax + Fuel pack SHELL TYPE 2000 JN Marshall

% Litres *C %

576 Litres of HSD 60 *C 60-70 %

510 Litres of FO 80-90*C 98 %

Performance and Specific fuel consumption Parameter FO consumed for 100 ml production FO consumed for 500 ml production Heating period for 100 ml (Autoclave) Heating period for 500 ml (Autoclave) Distilled water output from Multicolumn Temperature attained in Multicolumn COIL TYPE Boiler 800 lit 1100 lit 55 Minutes 66 Minutes 200 Litres 145 *C SHELL TYPE Boiler 450 lit 760 lit 35 Minutes 50 Minutes 275-300 Litres 153*C

Problems faced with COIL TYPE boilers: y Nozzle Choking, cleaning required during every shift y Coil Choking, Regular maintenance y Wet steam y Poor response to load fluctuations

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Energy Conservation Study At UNICHEM LAB, GHAZIABAD

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Process Benefits with SHELL TYPE Boilers y Dry steam & High process efficiency. y Reduced batch timings y Expensive maintenance downtime averted.

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Energy Conservation Study At UNICHEM LAB, GHAZIABAD

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Budgetary Quote SL. NO . 1. ITEM DESCRIPTION QTY Approx. Total Price

NATURAL Gas fired boiler 2000kg/hr F&A 100C operating at 10.5kg/cm^2 pressure High pressure Gas Train

27,00,000

3,50,000

Online Boiler Efficiency Monitoring System EFFIMAX 2000 Boiler House Changeover

11,00,000

41,00,000

Pressure reduction Stations(IV, MS, PC01, Strainer, PRV) Compact Steam Trap Modules(PC01)

6,00,000

1,10,000

Condensate Recovery System(FV, PPPPU, DH)

5,00,000

Plant Utiliasation and Recovery

12,10,000

Total investment for Boiler House= Rs.41,00,000 Total Savings = Rs. 19,00,000 ROI = 22 months

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Energy Conservation Study At UNICHEM LAB, GHAZIABAD

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PARTIAL LIST OF CONVERSIONS Sr. No. 1 Plant Dr. Reddy's Lab. Hyd. Miami Pharma. Pune 2 Harman FinoChem, Aurangabad Bal Pharma, pune Pharma Industry Pharma Pharma Replacement 3x 600 replaced with 3 TPH IBR 400 x 3 nos + 600 x 1no, replaced with 1120 kg/hr x 1no IBR 600x 2nos replaced by 2000kg/hr x 1 nos 400 x 3nos + 600 x 1nos replaced by 2000kg/hr x 1nos 850x 2nos replaced by 2000kg/hr x 1nos 600 x 1nos + 850 x 1nos replaced by 1100Kg/hr Measure 230 lit/hr Diesel- 164 lit/hr FO 300 ltrs/day of FO with additional steam using equipment 43500 lts Diesel/month- 39925lts FO/month 576lts of HSD to 510 lts of FO

Pharma

4 Cipla Patalganga 5 Grand Organics, Goa Pharma Pharma

50Kl/month LDO to 45Kl/month FO 25000lts of FO to 20000lts of FO

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