Chemical Plant Questionnaire

Instructions
The questionnaire will be used to collect the energy consumption data, process and equipment details of the
Insert additional rows as required.
The questionnaire consists of the following sheets:
Basic Details Provide some basic information of the plant
Production
Energy Use
Production Equipments
Provide information regarding equipment in the facility
Motors
Utilities
Other details
The following documents should be attached separately.
(a) List of inventory if readily available
(b) 12 months energy bills
(c) 12 months fuel bill
(d) Process flow of the facility
(e) Any other relevant information like expansion plan, addition of new equipment etc.
(f) Photographs of facility
(g) Equipment inventory in the facility (Production)
(h) Equipment inventory in the facility (Utility)

Provisions required:
1. Size of the ducts for air/flue gas measurement, provisions for flow measurement in straight sections, pressure, tem
suction and discharge , baghouse inlet and outlet, cyclones inlet and outlet, each stage in preheater , boiler circuit, d
work.

2. For Pumps (different pipe sizes (Minimum and maximum) , provisions for suction and discharge pressure measure
gauges working before field work
3. Details of the evaporators and other process systems.
4. Safe access for measurement during field study (Scaffolding/ safety ladder etc)
5. Checking the thermowells/temperature measurement provisions.
nergy consumption data, process and equipment details of the unit

eets:
nformation of the plant

egarding equipment in the facility

eparately.

lan, addition of new equipment etc.

provisions for flow measurement in straight sections, pressure, temperature and flue gas measurement at various sections (fan
cyclones inlet and outlet, each stage in preheater , boiler circuit, dust collection system). Need to check these ports before field

maximum) , provisions for suction and discharge pressure measurements/pressure gauges are required). Need to check pressure

stems.
(Scaffolding/ safety ladder etc)
ement provisions.
us sections (fan
ports before field

to check pressure
 Contract
Source of Power supply Billed Demand, Minimum PF
Demand,
EB/TG/DG kVA/kW Reqd. by SEB
kVA/kW

Description Nos. Rating

Transformer (kVA)
DG / TG (kVA)
Capacitors (kVAr – HT/LT)
PCCs
MCCs

Other Data Required

Electrical Single line diagram of the plant

Overall plant layout
Copy of recent electricity bills
Month-wise electricity consumption from grid for the period (last 3 years)
Month wise electricity generated by Diesel Generator set / own generation , (last 3 years)
Month-wise power factor and maximum demand recorded for above said period
Month-wise fuel consumption (last 3 years)
Ultimate & Proximate analysis for fuel including calorific values
Monthly product wise production details doe the period (last 3 years)
Monthly section wise consumption from grid + CPP + DG) (last 3 years)
Process Flow Diagram/Chart
 Average Power
Factor

(last 3 years)
riod
PRODUCTION CAPACITY (Product wise) SPECIFIC ENERGY CONSU
All Datas are for the period from 01.04.2022 to 31.12.2022

Annual
Production Annual Actusl Capacity Utilization
Sr. No Product Capacity, Tons Production, Tons (%) Sr. No
1 Caustic Soda 13500 4305 32 1
2 Bromine 2250 1197 53 2

RAW MATERIAL CONSUMPTION

Annual
Sr. Raw Material Consumption,
Tons
SPECIFIC ENERGY CONSUMPTION (Product wise)

Electricity
Thermal , Overall, Thermal Electricity
Product Toe/ton kWh/ton kcal/ton Sr. No Product GJ/Ton , GJ/ton
Caustic Soda 2752 1 Caustic Soda 3.58 9.9
Bromine 1551 2 Bromine 0.65 5.58
Overall,
GJ/ton
13.48
6.23
ENERGY USE

Primary Energy Annual

Sr. No Source Consumption Annual Cost, Rs
1 Coal, tons
2 Natural Gas, scm
3 Furnace Oil, tons

Diesel Consumption,
4 litres
5 Other fuel

Annual
Secondary Energy Consumption, Annual
Sr. No Source Demand, kVA kWh Cost, Rs.

Electricity (Purchased
1 from grid)
2 Electricity for CPP
Electricity from Diesel
3 Generators

Coal (Last 12 months)

Average
Consumption Average GCV
S. No. Period Cost
Tonne Kcal/kg INR/Tonne
1
2
3
4
5
6
7
8
9
10
11
12

Total Electricity from Grid + CPP + GD (Last 12 months electricity data)

 Energy Equivalent
S. No. Period Consumption Amount

kWh INR
1
2
3
4
5
6
7
8
9
10
11
12

Electricity from Grid (Last 12 months electricity data)

Energy Maximum Reactive Excess

Actual Demand Power
S. No. Period Consumption Demand Power Demand
Factor
kWh kVA kVA kVaH kVA
1
2
3
4
5
6
7
8
9
10
11
12
Amount

INR
PRODUCTION EQUIPMENT

1. Reactors
Type of operation
Sr. No. Reactor Type Motor KW Batch / Continuous
1 CSTR 11 Continuous
2 CSTR 7.5 Continuous
3 CSTR 1.1 Continuous
4 CSTR 0.75 Continuous

2. Distillation Columns

Sr. No.
Type of distillation
column Packed / Tray 1
Feed Qty kg/hr. 500
Feed Temperature 0C 35
Reflux ratio
Top product Qty kg/hr. NA
Top Product
Temperature 0C NA
Bottom product Qty kg/hr. 432
Bottom Product
Temperature 0C 30
Steam consumption kg/hr. 125
Column Diameter Mtr. 0.3

3. Dryers
Sr. No.

Tray / Spray/
Type of Dryer Fluidized etc.
Feed Qty kg/hr.
Feed Temperature 0C
Product Qty kg/hr.
Product Temperature 0C
Feed Moisture kg/hr.
Product Moisture kg/hr.
Steam consumption kg/hr.

4. Evaporators
 Steam
Evaporator No Pumps* KW Consumption kg/h
1 75 6000 Circulator
35 Pumps

* Feed pumps, Recirculation pumps, Transfer pumps etc.

5. Other equipments
Provide list of all other equipments used in production process with deisgn details
5.1 Absorption column
5.2 Carbonation column
5.3 Calciner
5.4 Crystallizer
240 1800 432 10368

0.3
 Design

Model Rated
No/ Serial FLP/Non Power,
SI. No Motor ID Type Make IP Class No FLP Frame Phase KW/HP

Other data required

Pl. specify all details of major equipments
 Power Frequenc Speed, Efficiency, Efficiency
Volts Amps Factor y, Hz RPM % Class
UTILITIES

1. Boilers

Rated Steam
Pressure, Operating Steam
Boiler no. Fuel used kg/cm2g Rated capacity Tons/h Pressure, kg/cm2g

2. Hot Air Generator (HAG)

Rated Capacity Operating Capacity,

HAG no. Fuel used kcal/h kcal/h

3. Air Compressors

Design

SI. No Compressor ID Type Rated FAD, CFM Rated Power, KW

Air Compressor IR 20 15

4. Pumps

Design

SI. No Pump ID Flow Rate, m3/hr Pressure, Kg/cm2 Speed, RPM

1 P - 271 380 1440

 2P - 273 320 1440
3P - 274 164 1440
4P - 275 90 1440
5P - 401 40 2900
6P - 402 0.11 1400

5. Chillers

SI. No Area Name Chiller Type* Running Hours Capacity, TR

* Reciprocating, Screw, Scroll, Centrifugal or Absorption Chiller

6. Cooling Towers

Cooling load Pumps

Cooling Tower No Type kcal/h Flow
Motor KW
m3/h
Thermopack Induced Draft 93 685
NBE Induced Draft 75 550

7. Vacuum Pumps

Vacuum Level Capacity Motor rating

Sr No. Vacuum Pump Type*
mmWC m3/h KW

* Liquid Ring type, Roots blower, Water Ejector, Steam Ejector etc.

8. Fans & Blowers

Design

SI. No Fan ID Flow Rate, m3/hr Pressure, Kg/cm2 Speed, RPM

NCP-1 Air Blower 17000

NCP-1 Air Blower 10000
NCP-1 Air Blower 25000
Operating Capacity,
Tons/Hr

Transmis Operating Cut in & Cut VFD Year of

Design Pressure, Speed, End User
sion Pressure, off Pressure Details, if Installati
Kg/cm2 RPM Details
Type Kg/cm2 Kg/cm2 any on

VFD Year of
Efficiency, % Details, if Installati Head, M Power, KW
any on
45 75
 40 37
12 22
30 15
45 15
0.37

Refrigera Rated Operating Year of

Power, KW
nt used COP Temperature Installation

ps Fans
VFD Details, if
Head Motor Air flow any
m kW m3/h
38 11
34 22

VFD Year of
Efficiency, % Details, if Installati
any on
Flow Diagram of Process

Any Special Problems or Areas for Study (Please describe in few lines)
Description of Process