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First Prize Chemicals

UPL LIMITED, UNIT-2Ankleshwar (Gujarat)

Unit Profile

�UPL Limited� formerly known as United Phosphorus Ltd. is a global generic cropprotection, chemicals and seeds company, headquartered in India (Mumbai). UPLstarted as small scale unit in 1969 to manufacture red phosphorus, now UPL Limitedis 3rd generic agrochemical company globally, Holds more than 136 patents and >4,900 registrations, globally, Revenues > USD 2.03 bn with a CAGR of 22% (2006-2016), 28 manufacturing locations across 3 continents (Asia, Europe and Latam).UPL fantastic growth is the result of successful backward and forward integrationby taking advantage of the consolidation opportunities within the agrochemicalindustry.

UPL is equipped with Dedicated Energy excellence cell, which comprises of 7BEE Certified Energy Auditors along with 32 plant coordinators.

UPL unit -02 started its operation in 1993, 16.2 acre plant is ISO 9000, ISO 14000and ISO 18000 certified manufacturing unit, UPL manufactures majorly Acephate,Devrinol, Phorate, Turbophos and other agro & specialty chemicals at its unit-02site. Unit has adopted 5S workplace organization method for improving efficiencyand effectiveness. Core energy team has qualified ISO 50001 internal auditor toperuse EnMS.

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Specific Energy Consumption

UPL has adopted innovative technology, renewables, Heat integration (Pinch)methodology, say, MVR, DVP, Inline condenser cleaning system, Air compressorHeat recovery, LED lights, Harvesting solar light through light pipes, Column andFFE Heat integration, substitution of refrigeration load with natural cooling. Few ofmeasures are shared below.

1. Steam and water conservation by MVR (Mechanical vapor recompression

system) for ZLD RO Reject. ( First Agro chemical company to achieve

ZLD with MVR)

The Unit has installed ZLD RO Systemwith 200 KLD capacity to recycleeffluent and become Zero DischargeUnit since May 2014, resulted ZLD ROreject of 10000 ppm TDS of 15-20 KLDand evaporated through conventionalevaporator utilizing 16-22 MT steamper day.

To eliminate steam for evaporation,unit has installed Mechanical Vapor Re-

PLC View of MVR System

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compressor system, which increases concentration of RO reject from 1% to 15%,Recovering 90% water and thus reducing thermal energy by 90%.

2. Conservation of thermal energy though Heat integration (pinch analysis)in Multi column operation.

Three column are in operation in the plant with different temperature and thermalrequirement. By thermal integration UPL utilized EA HB condensation heat to preheatMDC column re boiler and EA LB column Feed was preheated through condensationheat of same column as indicated in sketch.

Column Operation before pinch Column Operation After pinch

MDC Pinch HRU Function of Spiral HE

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3. Conservation of Power, Steam, Solvent, Lub. oil by adopting �DryVacuum pump in place of once through Lubricated vacuum System( OTL)

The unit has replaced 7 Nos of OTLvacuum system with Dry vacuumpump. Benefits: Reduced Power andsteam consumption along with wastereduction. Achieved higherequipment reliability and betteroperational control. Now solventrecovery is possible without Energyconsumption for separation of wasteoil. The power consumption of dryvacuum system is reduced by 30%.

4. Substitution of Refrigeration power with Natural cooling for MDCFFE & Column.

The plant used 240 TR plus 105 TR of chilled water to condense MDC vapor atTemperature 39.5 deg C, Designed cooling water condenser with very low approachto condense MDC vapor even at 34 deg C. This was possible with low approachdesign Plate HE or Spiral HE, unit selected spiral HE Condenser to maintain samepressure drop in the system. This eliminated the foot print of large refrigerationsystem, power and water.

DVP installed in production block

180m2 Spiral HEMDC FFE

90m2 Spiral HEMDC Column

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5. Innovative in-line condenser cleaning system to sustain Heat

transfer coefficient

Most chemical industry suffer issue on deviations of �U� due to fouling on Coolingwater side. Normally clean condenser give approach below 1 deg C ( Approach =condensing temp � Cooling tower outlet temp), with time say after 1 week startsincreasing gradually, once approach reaches 10 deg C, it is due cleaning in orderregain Performance. Typical cleaning frequency is every quarter. Higher specificpower consumption was observed Every 4 deg. rise in condensing temperature isloss of @ 10% of energy, unit adopted inline condenser cleaning system to sustainSPC to design value and avoid manual cleaning and shutdown, Now approachsustained below 1 deg C. throughout year.

Picture of online condenser cleaning system

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Second Prize Chemicals

IOL CHEMICALS ANDPHARMACEUTICALS LIMITED

Barnala (Punjab)

Unit Profile

IOL Chemicals and Pharmaceuticals Limited is a chemical manufacturing industrylocated in Barnala in Punjab. IOLCP began with a small project of Rs. 65 million tomanufacture 4500 TPA of Acetic Acid and has now diversified into a multi productcompany to manufacture the 87000 TPA Ethyl Acetate, 5200 TPA Acetyl Chloride,7200 TPA Mono Chloro Acetic Acid and 9000 TPA Iso Butyl Benzene. IOLCP iscertified with ISO: 9001, 14001, 18001, Halal And Kosher certification and Strongmarket presence in 47 countries.

Energy Conservation

Energy conservation continuous to be an area of major emphasis for IOL chemicals& pharmaceuticals limited. They have been continuously putting efforts to reducespecific energy consumption by both improving the technology and energyefficiencies. They consider energy management as a team approach and includedthis under the Total Quality Management. Unit is aware that conserving energy isdesirable not only to reduce costs but also for conserving precious & fast depletingfossil fuel reserves and protecting the environment.

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OBJECTIVESTo procure and manage energy supplies and their use in the most cost effectivemanner consistent with the industry�s wider objectives and the resources available

Energy Conservation Cell Structure

Specific Energy Consumption

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Description of Energy Conservation Measures Implemented:

1. Process upgradation by installation of sparger in flash tank 02 ofMCA column feed tank in Mono Chloro Acetic Acid plant: Sparger is installedin the flash tank 02 which strip out the dissolve uncondensed gases from the feedwhich increase the vacuum of the MCA column & by increasing the vacuum in thecolumn the steam consumption in the distillation column decrease.

Total Electricity savings - 18.48 lacs

Total steam savings - 109.88 lacs

Total investment - 5 lacs

Payback period - 1 month

2. Use of high pressure steam condensate in steam tracing for replacinglow pressure steam in Mono Chloro Acetic Acid plant: High pressure steam isused in the distillation section of the mono chloro acetic plant. Previously , thishigh pressure steam condensate was sent to the condensate tank. After modification,high pressure steam condensate is used in steam tracing lines of mono chloroacetic acid to keep it in molten state where previously low pressure steam wasused hence the low pressure steam is saved.

Total steam savings - 60.19 lacs

Total investment - 2 lacs

Payback period - 1 month

3. Replacement of chiller with cooler PHE in final distillation column ofEthyl Acetate plant: Initially chilled water was used to subcool the condensedmaterial of final distillation column. Chillers of final distillation column of ethyl acetateplant which uses chilled water as a cooling medium,was replaced with coolers ofhigher heat transfer area, which uses cooling tower water. This reduces chilledwater consumption of the ethyl acetate plant.

Total Electricity savings - 36.38 lacs

Total steam savings - 36 lacs

Total investment - 8.5 lacs

Payback period - 2 months

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4. Use of flash steam generated in Iso Butyl Benzene plant: High pressuresteam (27 Kg/cm2) is used in Iso butyl benzene plant distillation section . Initiallylow pressure steam (5 Kg/cm2) was used in recovery section. After modification,Flash steam generated from high pressure steam (27 Kg/cm2) condensate is usedas low pressure steam in recovery section so low pressure steam consumption isreduced in recovery section.

Total steam savings - 33.60 lacs

Total investment - 3 lacs

Payback period - 1 month

List of Energy Conservation Projects Implemented in year 2015-16:

Project description Achievement of Annual energy savings in 2015-16

Electricity Fuels* Investment(Lakh Steam Total savings incurred onkWh) (MT) Rs. Lakhs) the project

Rs. (Lakhs)

1 Use of high pressure steam condensate insteam tracing for replacing low pressure steamin Mono Chloro Acetic Acid plant. 3762 60.19 2

2 Process upgradation by installation of spargerin flash tank 02 of MCA column feed tank inMono Chloro Acetic Acid plant. 2.4 6868 128.42 5

3 Installation of preheater in acetyl column feedline in Acetyl Chloride plant 3207 51.31 11

4 Process optimization is done to use low flowcooling water pump instead of high flowcooling water pump in winter season 2.44 18.77 7

5 Automization is done in steam ejector steaminlet line to control the steam pressure forreducing the steam losses in Acetyl Chlorideplant 2455 39.28 5

6 Increase in catalyst composition in MCAreactor by studying the reaction kinetics whichimproved the productivity at same utilities. 3524 56.38 4

7 Installation of Variable frequency drive on gasblower in Iso Butyl Benzene plant 0.996 7.67 3

8 Installation of toluene preheater to reducebatch timing and reactor washing frequency inIBB plant 0.36 2.76 5

9 Reduced steam consumption by optimizingreflux ratio in Iso Butyl Benzene plant byusing simulation software 0.64 2640 47.17

10 Installation of additional cold oil PHE In IsoButyl Benzene plant utility section 2.24 3750 77.21 20

11 Use of flash steam generated in Iso ButylBenzene plant 2100 33.60 3

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12 Installation of interchanger PHE to use thechilled reflux stream of distillation columnas cooling media in Ethyl Acetate plant 3.15 1500 48.26 7

13 Installation of new reactor with sparger inEthyl Acetate plant. 1.98 15.25 35

14 Replacement of chilled water with coolingwater in crude chiller during winter season inEthyl Acetate Plant 0.47 225 7.24 3.5

15 Replacement of chiller with cooler PHE in finaldistillation column of Ethyl Acetate plant. 4.73 2250 72.38 8.5

Total 19.40 32281 665.9 119

Energy Management Policy

We, IOL Chemicals and Pharmaceuticals LTD, are committed to conserve energy atall levels, to be competitive and save Environment through following ways:

� Adopting best energy management practices.

� Regularly monitoring energy use.

� Reporting quarterly on energy use to staff and at Management Board meetings.

� Establishing an Energy Management organization structure.

� Encouraging Energy Managers of significant facilities to initiate EnergyManagement Committees and/or Energy Champions for their facilities.

� Ensuring that new appliances, equipment, and building projects are energyefficient.

� Identifying all areas of opportunity for improved energy performance via detailedconsultation with staff.

� Facilitate developing and implementing an action plan.

� Checking the effectiveness of energy saving measures, periodically documentany changes in procedures resulting from process improvement, and makecomparisons with objectives and targets.

� Continual interaction with the technology suppliers and visits and interactionwith best alcohol based plants in India and benchmarking various parametersis an ongoing exercise at chemical division.

� Everyday energy consumption is reviewed in daily coordination meeting andcorrective actions are taken best achieved consumption is taken as target.

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Certificate of Merit Chemicals

UPL LIMITED, UNIT-1Ankleshwar, District Bharuch (Gujarat)

Unit Profile

UPL unit - 01 started its operation in 1980, Plant is ISO 9000, ISO 14000 and ISO18000 certified manufacturing unit, UPL manufactures majorly Monocrotophos,Dichlorovos, Trim ethyl Phosphite, Mancozeb, IKI and other agro specialty chemicalsat its unit-01 site. UPL have adopted 5S workplace organization method for improvingefficiency and effectiveness.

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Specific Consumption:

H1- Half Yearly (April�2016 to Sep�2016)

At Unit-1, plant has adopted innovative technology, renewable energy and Heatintegration (Pinch analysis). For example Heat pipe for low grade heat recover, LEDlights, harvesting solar light through light pipes, rain water harvesting, ColumnHeat integration, Heat recovery from Air compressor, use of gravity for pumping(single circuit). Few of measures are as shared below,

Energy Conservation Projects Implemented:

1. Steam & power reduction by �Pinch analysis�. Waste heat of Ammoniadistillation column used to preheat stripper column feed.

Before: Bottom stream of ammonia recovery column was cooled from 195 to 50Deg C by cooling water. Simultaneously feed of Ammonia stripper was preheatedfrom 85 to 95 Deg C by fresh steam.

After: Using �Pinch Analysis� of adjacent ammonia stripper & recovery column,heat recovery potential identified. Ammonia stripper-1 feed was preheated usingammonia recovery column bottom stream. Steam is saving achieved 1000 Kg/hrand cooling water load also decreased by 180 TR. CW pumping power reducedalong with 21 KLD water loss due to evaporation.

Actual pics of installationSketch after Modification

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2. Steam reduction by Multi column heat integration and reduce columnre-boiler steam load.

Before: C906 & C904 column is operated on 100 & 115 Deg C respectively byfeeding fresh steam. Both column bottom stream was cooled by cooling water andheat dissipated to atmosphere through cooling tower.

After: Instead of discharging waste heat to atmosphere, C906 re-boiler feedpreheated by using C904 bottom withdrawal stream. Hence re-boiler load of C906reduced, steam consumption in C906 reduced by 400 Kg/hr. Cooling water loadalso reduced at C904 cooler.

Sketch before Modification Sketch after modification

3. Use of gravity flow resulted in operation of only secondary pumpinstead of primary & secondary in all operating Chiller system.

Before: Primary & secondary pump were running in all operating chillers (8 Nos).

After: Normally hot well & cold well system used for variable load since there iscontinuous requirement of chilled water. Using gravity flow of return chilled water,It is directly fed to chiller instead of hot well. Cold water is being circulated toprocess by only secondary pump. Ensuring minimum flow requirement of chiller.

Sketch before Modification Sketch after modification

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4. Use of �Heat Pipe� for Natural Gas reduction by Spray dryer inlet airpreheating using waste heat of exhaust flue gas

Before: Ambient air was heated to 190 Deg C in indirect fired hot air generatorfor drying of Mancozeb slurry. Flue gas from hot air generator at 288 Deg C wasvented to atmosphere.

After: Ambient air before going to hot air generator is preheated to 116 Deg Cusing waste heat of flue gas, hence reduction in Natural gas achieved by 15 sm3/hr. Also flue gas temp reduced to 139 Deg C.

Heat pipe is used because it has high heat transfer coefficient 20 Kcal/Hr.m2.Deg Cfor air to air heat transfer whereas normally finned type heat exchanger HTC comes10-12 Kcal/Hr.m2.Deg.C. There is benefit on heat transfer area.

Installed Heat pipe Heat pipe working Principle

5. Use of high efficient Hybrid vacuum system in place of Steam jetejector system

Before: Vacuum for solventrecovery and process applicationare maintained from 100 torr to10 Torr using two stage to fourstage steam ejector system.Over the period of operationsteam nozzle gets erode andthere was issue of vacuum dropsand high steam consumption.

After: To get vacuum at lowestcost, vacuum requirement up to50 torr, Water ring vacuumpump installed and less than 50torr, 2stage steam ejector +water ring vacuum pump installed.Steam consumption drastically reduced from 1800 kg/hr to 700 Kg/hr with additionalpower consumption 70kwh.

Installed water ring pump