Study and Improvement in Operations of Chemical Plant

STUDY AND IMPROVEMENT IN
OPERATIONS OF CHEMICAL PLANT
GROUP MEMBERS
SIDDESH NAIK
PRATIK PARSEKAR
MOHIT KESARKAR
ANJOOM NAIK
(111102044)
(111102050)
(111102061)
(111102040)
GUIDE:- SHRI. MAHESH DHAWALIKAR
OBJECTIVES ACCOMPLISHED
Boiler study and boiler efficiency calculations.
Ways to improve boiler efficiency.
Preventive maintenance program for boiler.
Layout and cost of reactor automation.
Suggestions in 5S.
IMPLEMENTATION COST AND SAVINGS

Sr.no
Methods used
Cost of
Savings per year in
implementation in
Rupees
Rupees
1
Installing an economizer
90,000
1,08,405
Use of solar energy to heat boiler

feed water
6,68,826
90,301
Automatic TDS blowdown system
1,50,000
3,06,600
Economic Thickness of Insulation
13,250
2,18,767
Reactor automation
85,56,000
13,04,395
BOILER EFFICIENCY CALCULATIONS
Boiler efficiency=
= %
Efficiency =
=62.22%
Calculated efficiency of boiler at esteem industry=62.22%
WAYS SUGGESTED TO IMPROVE EFFICIENCY

1.
Reduce excess air
2.
Install an economizer
3.
Economic thickness of insulation
4.
Solar power to heat boiler feed water
5.
Automatic blowdown system
1.SOLAR ENERGY TO HEAT BOILER FEED WATER
Solar power can be used to heat the feed water from 45C to 60 C
which will lead to fuel saving.
Total water required per day = 21KL
Q = m*cp*dT
Q = 21000*4.19*(60-45)
= 1319850/(24*3600)
= 15.27 Kg/sec
= 15.27 KW
Cost for the installation of solar plant = 0.73$per Watt

Cost for the installation of solar plant = 15.27*1000*0.73*60
= Rs 668826
For 10 hour cost of fuel = Rs 12370
Considering 2% of fuel cost saved.
Total amount saved per day= Rs 247.4
Period required to overcome the cost of solar plant= 7.4 years
The life of the solar plant will be 20 years . Therefore for 12.6 years less
amount of fuel will be required
AUTOMATIC TDS BLOWDOWN SYSTEM
AUTOMATED BLOWDOWN COST JUSTIFICATION
Boiler produces-3000Kg/hr
TDS level to be maintained-18-22 ppm
Records at esteem show that ppm has been maintained at an average

-19ppm.
With automatic TDS this value can be increased to 21ppm without
exceeding 22 ppm.
This would decrease blowdown by - (21-19)/19=10.52%
Typically 19 ppm results from 10 cycles. Blowdown required to maintain

10 cycles = 3000/10 = 300Kg/hr
If 300kg/hr is reduced by 10.52% thats a saving- 0.1052*300
= 31.56Kg/hr
To heat 31.56Kg/hr fuel cost required = (31.56*5)/4.44

= 35 Rs/hr
Cost of implementation = Rs1,50,000/
Payback period=1,50,000/35 = 4285.71hrs

= 6 months
5.ECONOMIC THICKNESS OF INSULATION

DESCRIPTION
Length of pipe, L
Bar pipe outer dia. ,D1
Bare pipe surface area , A
UNIT
1 INCH
2 INCH
3 INCH
50
50
50
mm
76.2
76.2
76.2
23.9268
23.9268
23.9268
30
30
30
120
120
120
50
50
50
glass wool
glass wool
glass wool
85
85
85
0.036
0.034
0.032
0.95
0.95
0.95
0.13
0.13
0.13
Sq. m
Ambient temperature ,Ta
Degree Celsius
Bare pipe wall temperature,Th
Degree Celsius
Desired wall temp. with insulation ,Tc
Degree Celsius
Material of insulation
Mean temp. of insulation ,Tm
Specific conductivity of insulation
Surface emissivity of bare pipe
Surface emissivity of Al cladding
Degree Celsius
DESCRIPTION
UNITS
Surf. Heat transfer coeff. of hot bare

surf., h=(0.85+0.005(Th-Ta))*10
Watt/sq.m celsius
Surf. Heat transfer coeff. After

insulation, h=(0.31+0.005(Tc-Ta))*10
Watt/sq.m celsius
Thermal resistance, Rth=(Th Tc )/

(h*(Tc-Ta))
Thickness of insulation , t=Rth*k
R1=outer dia./2
Teq=R2*ln(R2/R1)
Outer rafius ,R2
1 INCH
2 INCH
3 INCH
13
13
13
4.1
4.1
4.1
Celsius sq.m/watt
0.853
0.853
0.853
mm
30.7
mm
38.1
mm
30.7
mm
62.35
29.024
38.1
29.024
61.21
27.2
38.1
27.2
60
DESCRIPTION
Thickness of insulation
UNITS
1 INCH
2 INCH
3 INCH
mm
24.25
23.11
21.9
19.58
19.2296
18.8495
27.994
27.994
27.994
4.415
4.336
4.25
23.579
23.658
23.744
8000
8000
8000
188632
183264
189952
Insulated pipe area , A

Total losses from bare surf. ,
Q=h*A*(Th-Ta)
KJ/sec
Total loss from insulated surface,

Q=h*A*(Tm-Ta)
KJ/sec
Power saved by insulation

P=(Q-Q)
KJ/sec
Annual working hours , n
hrs./year
Energy saving after insulation

E=P*n
KWh/year
COST SAVINGS
Heat energy cost = calorific value of fuel*mass of fuel per second*hours of operation
annually
=14644*225/3600*8000
=73,22,000 KWh/year
Fuel cost annually = fuel cost /Kg*fuel fed/hour * annual hours operation
= 5*225*8000
= 90,00,000 Rs/year
Heat energy cost = 9000000/7322000

= 1.23 Rs/KWh
1. Savings with 1 inch thickness = 1.23*205224

= 2,32,425.52 Rs/year
Implementation cost = 50*265
= 13,250/ Total savings = 232425052-13250
= 2,19,175.52 Rs/year
2. Savings with 2 inch thickness = 1.23*205488

= 2,52,750.24/year
= 18,500/ Total savings = 252750.24-18500 = 2,34,250.24 Rs/year
3. Savings with 3 inch thickness =1.23*205784

= 253114.32Rs/year
= 25,000/ Total savings = 253114.32 - 25000
= 228114.32 Rs/year
The data above shows that 2 inch thickness gives maximum cost savings
and hence is the economic thickness of insulation.
Thus we can conclude that implementation of 2 inch thickness will reduce
heat loss.
PREVENTIVE MAINTENANCE OPERATION FOR BOILER

1.Installing meters on makeup water lines to monitor flow.
2. Blowing down routinely without overdoing it. Excessive blow-down wastes
water, chemicals and energy.
3. Checking insulation on piping and storage tanks.
4. Cleaning and inspecting water and fire tubes regularly to reduce scaling.
5. Checking safeties, including primary and auxiliary low-water cutoffs, gauge

glass, pressure controls, scanners, and pressure switches.
6. Tuning boilers regularly to optimize performance.
7. Inspecting steam traps and steam lines routinely for leaks.
COMPONENTS FOR AUTOMATION

1.Sensors
2.Remote terminal unit/PLC
3. Telemetry
4.Supervisory system
5.HMI (Monitor)
1.SENSORS
Temperature sensors
RTD(resistance temperature detectors)
INFRARED THERMOMETER
PRESSURE SENSORS
Elastic Sensors
Electric Sensors
2. RTU(A REMOTE TERMINAL UNIT)
A remote terminal unit (RTU) is a microprocessor-controlled electronic device

that interfaces objects in the physical world to a SCADA .
It convert sensor signals to digital data.
They have telemetry hardware capable of sending digital data to the
supervisory system, as well as receiving digital commands from the
supervisory system
3. HMI
HMI interface present data collected from Remote Telemetry Units (RTUs) and
Intelligent Electronic Devices (IEDs).
Without an HMI installed within the SCADA network, operators would be
unable to see or act upon the data gathered by RTUs and individual sensors.
4. SUPERVISORY SYSTEM
SCADA (supervisory control and data acquisition) is a system operating with

coded signals over communication channels so as to provide control of remote
equipment.
It is a main supervisory system where action are taken and operator can
change process parameters as per the process requirements.
SPECIFICATION AND EXAMPLES OF REACTOR

COMPONENTS
SR.NO
COMPONENTS
TEMPERATURE SENSOR
SPECIFICATIONS
Temperature range :
373k-573k
EXAMPLE
RTD ,Thermocouples.
PRESSURE SENSOR
2
RTU/S
Pressure range:2kpa5kpa
Elastic sensor ,Electric

sensor
Ethernet IO (ADAM-6000
series)
High reliability, powerful

communication
capabilities
PLC
3
HMI
CONTROL SYSTEM
Ethernet IO (ADAM-6000
series)
Colour display,high
resolution.
Softwares: GENESIS64
AUTOCAD,SOLIDWORKS,C,C+
+,
IGGRAPHIX,LABVIEW, SCADA .
HMi04BU
IBM PC, Apple IIe,

Apple IIc and Amiga
500.
OVERVIEW OF REACTOR
AUTOMATED REACTOR
HOW SCADA(CONTROL SYSTEM)WORKS
A SCADA system, at the machine level, consists of a central station for

gathering data and managing the overall operation.
The RTU or the PLC collects the information locally and then passes it on to
the central station.
SCADA systems also allow staff or supervisors to change the settings as
appropriate at the level of the RTU or the central station.
Alarming conditions like high temperature can then be stored and displayed.
SUGGESTED COMPONENTS
Temperature sensor- Platanium RTD, cost of which is 5000/-
Pressure sensor: Electric sensor ,cost of which is 4000/-
RTU, cost of which is 27000/-
HMI- HMi04BU ,cost of which is 10,000/-
Control system-Apple Iieas ,cost of which is 3,00,000/-
Valve-solenoid valve, cost of each solenoid operated valve is 2000/-
OVERALL REACTOR AUTOMATION COST

Cost
of HMI = 10,000/-
Cost
of control system = 3,00,000/-
Cost
of sensors = 9,000/-
Cost
of RTU = 27,000/-
Cost
of solenoid operated valves =18,000/-
Total
cost of components = 3,64,000/-
Cost
of implementation of automation as per Autromatrix INC. =

20,00,000/Total
cost = cost of implementation of automation + cost of components.

= 20,00,000 + 3,64,000
= 23,64,000/-
5S SUGGESTIONS
1.
Mark reference materials with an oblique line to detect disorder from a distance.
2.
Store tools beside the machine with which they will be used according to
operations.
3. Organize files and store using color code to make it easy to identify.
4. Store similar items together.
5. Operators need to be trained to carry out routine maintenance of
machine.
7. Markings on the road separately for workers and vehicles.
8. Safety charts need to be put up everywhere.
sequence of work
RAW MATERIAL STORES PRESENT LAYOUT
Present height of racks = 3.27m

Height which can be utilized = 5m
Area of raw material store = 658.84sq m
Volume of raw material store =3294.2 m3
Calculations for the height of 3.27m.
Area of racks = 26.56+26.56*2+23.86*2
= 127.4sq m
Volume of racks = 416.598 cubic m
Volume Ratio = 416.598/3294.2

= 0.1264
Calculations for the height of 5m
Volume of racks if 5 m is utilized = 637 cubic m
Ratio volume = 0.19337
% increase in storage w.r.t present = (637-416.598)*100/416.598
% increase in storage w.r.t present = 52.9%
RAW MATERIAL STORE REVISED LAYOUT
Area of racks = (22.09*1)*2 + (22.09*2)*2+ (13.53*2)

= 44.18+88.36+27.06
=159.6sq. m
Calculations for the height of 3.27m with revised layout
For height = 3.27 m
Volume = 521.892 cubic m
Ratio of volume = 0.1584
increase w.r.t present = 25.274%
Calculations for the height of 5m with revised layout

Volume = 798 cubic m
Ratio of volume = 0.2422
increase w.r.t present = 91.55%
Ratio of volume=0.2422
% increase w.r.t present=91.55%
Volume ratio with original layout of raw material store =0.1264.
After revising the stack height to 5 m the volume ratio = 0.19337.
After changing the arrangement of racks ,% increase = 91.55 % .
If we incorporate the 5m stack height in the new arrangement

maximum achievable volume ratio = 0.2422.

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STUDY AND IMPROVEMENT IN

OPERATIONS OF CHEMICAL PLANT

GUIDE:- SHRI. MAHESH DHAWALIKAR

Boiler study and boiler efficiency calculations.

Ways to improve boiler efficiency.

Preventive maintenance program for boiler.

Layout and cost of reactor automation.

IMPLEMENTATION COST AND SAVINGS

Savings per year in

Use of solar energy to heat boiler

Automatic TDS blowdown system

Economic Thickness of Insulation

BOILER EFFICIENCY CALCULATIONS

WAYS SUGGESTED TO IMPROVE EFFICIENCY

Reduce excess air

Economic thickness of insulation

Solar power to heat boiler feed water

Automatic blowdown system

1.SOLAR ENERGY TO HEAT BOILER FEED WATER

Total water required per day = 21KL

Cost for the installation of solar plant = 0.73$per Watt

Considering 2% of fuel cost saved.

Total amount saved per day= Rs 247.4

Period required to overcome the cost of solar plant= 7.4 years

AUTOMATIC TDS BLOWDOWN SYSTEM

AUTOMATED BLOWDOWN COST JUSTIFICATION

TDS level to be maintained-18-22 ppm

Records at esteem show that ppm has been maintained at an average

Typically 19 ppm results from 10 cycles. Blowdown required to maintain

To heat 31.56Kg/hr fuel cost required = (31.56*5)/4.44

Payback period=1,50,000/35 = 4285.71hrs

5.ECONOMIC THICKNESS OF INSULATION

Ambient temperature ,Ta

Bare pipe wall temperature,Th

Desired wall temp. with insulation ,Tc

Surf. Heat transfer coeff. of hot bare

Surf. Heat transfer coeff. After

Thermal resistance, Rth=(Th Tc )/

Insulated pipe area , A

Total loss from insulated surface,

Power saved by insulation

Annual working hours , n

Energy saving after insulation

Heat energy cost = 9000000/7322000

1. Savings with 1 inch thickness = 1.23*205224

2. Savings with 2 inch thickness = 1.23*205488

3. Savings with 3 inch thickness =1.23*205784

PREVENTIVE MAINTENANCE OPERATION FOR BOILER

5. Checking safeties, including primary and auxiliary low-water cutoffs, gauge

COMPONENTS FOR AUTOMATION

2. RTU(A REMOTE TERMINAL UNIT)

A remote terminal unit (RTU) is a microprocessor-controlled electronic device

SCADA (supervisory control and data acquisition) is a system operating with

SPECIFICATION AND EXAMPLES OF REACTOR

Elastic sensor ,Electric

High reliability, powerful

IBM PC, Apple IIe,

HOW SCADA(CONTROL SYSTEM)WORKS

Area of racks = (22.091)2 + (22.092)2+ (13.53*2)