KUMAR ORGANIC PRODUCTS LIMITED

SOLID FUEL BOILER DOSSIER

Objective: Energy Conservation

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TABLE OF CONTENT Sl. No. 1 2 3 4 5 6 7 8 8.1 8.2 9 10 11 12 13 14 14.1 14.2 14.3 15 Content General Information about Utilities at KOPL Steam Requirement of KOPL Specification of Reactors at Shaureya Block Specification of Reactors at Jigani Unit Specification of Reactors at Pilot Plant Fuel Consumption at KOPL Calculation: -Fuel consumption of Steam Boiler at Jigani & Shaureya Calculation: -New Solid Fuel Boiler Conclusion: Expected Savings Payback calculation Land requirement & Selection Layout plan for new 3T steam Boiler Quotations for 3T steam boiler Comparison report of received quotations Schematic diagram of 3 T Solid Fuel Boiler Other details of new 3 T Steam Boiler Feed Water details Layout & Sizing of pipe line Chimney dismantling & Fixing Piping Layout for Jigani & Shaureya Block 10 11 12 12 13 14 15 16 17 17 17 18 18 Page No. 3 3 4 5 6 7 8

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1. General Information about Utilities at KOPL: At present KOPL are having three manufacturing facilities two of them at Jigani industrial area & third at Harpanhalli. Products manufactured at KOPL are at Jigani unit Triclosan, at Shaureya block Triclosan & Kopirox and at Harpanhalli Zinc Pyrithione. Jigani Industrial area is having two facilities Jigani plant & Shaureya block. Both the units are having separate utilities like: 1. Steam (LP & HP), 2. Cooling tower, 3. Chilling plant & 4. Thermo Fluid heating system. 2. Steam Requirement of KOPL: For steam requirement at both the units we are having non IBR boilers. In Jigani plant we have two 850 Kg/hr Furnace oil fired boilers are under operation & apart from that one more diesel fired boiler of capacity 600 Kg/hr is used in case of any breakdown or as per the requirement. On other side in Shaureya Block we have two 850 Kg/hr Furnace oil fired boilers. Steam is used at both units for process requirement & vaccum application. 1. Low Pressure (3-3.5 Kg/cm2) 2. High Pressure steam (8-10 Kg/cm2) Usage of steam: Main consumption of steam is in form of Low pressure. Low pressure steam is used for process requirement like heating of reaction mass, solvent recovery, drying of product etc., High pressure steam is required for generation of fine vacuum at distillation setup by using two stage steam jet ejector system. Detail lists of equipments of both plants where steam consumed are given below:

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5.

Unit operations where steam consumption required are Solvent recovery by Distillation, Drying (Fluid bed drier, Tray drier), Vacuum (By using steam jet ejectors). Apart from that Reactions temperature maintain & raw material melting like -2, 4 Di Chloro Phenol. From above mention operations Distillation is consuming more then 50% of steam. For Jigani & Shaureya Block two II-stage steam jet ejectors are there to generate the vacuum, for High Vaccum distillation unit by using steam @ 10 Kg/cm2. Steam consumption for each vacuum system is approximately 150 Kg/hr which is nearly 15-20% of total steam load. Apart from this remaining 30-35% steam is used for other operations in the plant.

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6. Fuel Consumption at KOPL: Furnace Oil is used as a fuel in Steam boilers & Thermo fluid heating system at KOPL (Jigani Unit, Shaureya Block & Harpanhalli unit). For Jigani unit High Speed Diesel is also used for Steam boilers & Thermo fluid heating system. FO & HSD consumption for Jigani unit & Shaureya Block is given in the below table on average basis. Table: Daily Furnace Oil consumption for Steam boilers in Jigani & Shaureya Sl. 1. 2. Manufacturing Total Average F.O. Consumption (Liter) 2000 1300 Jigani Unit Shaureya Block For Steam Boiler (Liter) 1700 1100 For Thermo Fluid (Liter) 300 200

No. Facility

Table: Daily HSD consumption for Steam boilers in Jigani & Shaureya Sl. 1. 2. Manufacturing Average HSD Consumption (Liter) 150 Jigani Unit Shaureya Block For Steam Boiler (Liter) 75 For Thermo Fluid (Liter) 75 -

No. Facility

From above table the average FO consumption for steam boilers at Jigani & Shaureya are 1700/1100 liters. For Jigani unit extra fuel i.e. HSD consumption for steam Boiler is 75 liters in case of any breakdown. Steam consumption of both units can be calculated on the basis of fuel consumed at boilers. Detailed steam calculation is given below.

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7. Calculation: -Fuel consumption of Steam Boiler at Jigani & Shaureya Data: 1. Bulk density of Furnace Oil = 900 Kg/m3 2. Gross calorific value = 10200 Kcal/Kg 3. Bulk density of Furnace Oil = 900 Kg/m3 4. Gross calorific value = 9500 Kcal/Kg 5. Cost of Furnace Oil = 31.5 Rs/Kg 6. Cost of High Speed diesel = 32 Rs/Kg 7. Efficiency of boiler = 70% 8. Latent heat of steam = 540 Kcal/hr 9. Average consumption of FO for Jigani & Shaureya= (1700 & 1100) liters/day 10. Average consumption of HSD for Jigani = 75 liters/day 1. Consumption of Steam by FO & Diesel per hr for Jigani Unit Average FO consumption/hr for Jigani unit = 1700/20 = 85 Liters/hr Or 85 x 0.9 = 76.5 Kg/hr Energy produced per hr = 76.5 x 10200 = 780300 Kcal/hr Steam produce per hr = (Energy x Boiler efficiency)/latent heat of steam Steam produce per hr = (780300 x 0.7)/540 = 1011.5 Kg/hr of Steam Say = 1015 Kg/hr of Steam Average HSD consumption/hr for Jigani unit = 75/20 = 3.75 Liters/hr Or 3.75 x 0.88 = 3.33 Kg/hr Energy produced per hr = 3.33 x 9500 = 31635 Kcal/hr Steam produce per hr = (Energy x Boiler efficiency)/latent heat of steam Steam produce per hr = (31635 x 0.7)/540 = 41.5 Kg/hr of Steam Say = 42 Kg/hr of Steam

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Total Average steam consumption for Jigani unit = 1015+42 =1057 Kg/hr Maximum load for Jigani unit can be taken @ 20% extra of average load = 1057 x 1.20 Maximum load for Jigani unit = 1268 Kg/hr or Say =1275 Kg/hr 2. Consumption of Steam by FO per hr for Shaureya Block Average FO consumption/hr for Shaureya Block = 1100/20 = 55 Liters/hr Or 55 x 0.9 = 49.5 Kg/hr Energy produced per hr = 49.5 x 10200 = 504900 Kcal/hr Steam produce per hr = (Energy x Boiler efficiency)/latent heat of steam Steam produce per hr = (504900 x 0.7)/540 = 654.5 Kg/hr of Steam Say = 655 Kg/hr of Steam for Shaureya Block Maximum load for Shaureya can be taken @ 20% extra of average load = 655 x 1.20 Maximum load for Jigani unit = 786 Kg/hr or Say = 800 Kg/hr Total max load steam for both the units = 2075 Kg or Say = 2100 Kg/hr 3. Steam Cost Total average steam consumption for both the unit is = 1057+655= 1712 Kg/hr Total Fuel consumption for both the unit is FO = 76.5+49.5= 126 Kg/hr HSD = 3.33 Kg/hr Steam Cost = Cost of fuel (FO+HSD) / kg of steam = ((126 x 31.5) + (3.33 x 32.5)) / 1712 Kg = 4077.25 Rs/1712 Kg of steam = 2.38 Rs /Kg Assuming cost of power = 0.1 Rs/kg Manpower cost = 0.02 Rs/Kg Total cost of steam = 2.38 + 0.1 + 0.02 = 2.5 Rs/Kg Say- 2.5 Rs/Kg

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8. Calculation: -New Solid Fuel Boiler As maximum combined steam load for both units is = 2075 Kg/hr Say = 2100 Kg/hr is the maximum load of steam for the both units Assuming 20% extra capacity for future expansion so capacity of new boiler = 2100 x 1.2 = 2520 Kg/hr As per above calculations it will safer to go for boiler of capacity =3000Kg/hr Basis: Boiler Capacity 3000 Kg/hr Data: 1. Bulk density of wood = 700 Kg/m3 2. Gross calorific value of briquette = 3700 Kcal 3. Cost of wood = 3.5 Rs/Kg 4. Efficiency of boiler = 68% 1. Consumption of wood per hr M x = G.C.V x Mass of briquette Mass of Wood = (M x ) / G.C.V = (3000 x 540) / 3700 = 437.8 Kg/hr But Efficiency is 68% Actual Wood consumption per hr = 437.8 / 0.68 = 643.8 Kg/hr Say 650 Kg/hr 2. Space requirement for wood storage Basis: 24 hrs operations and 4 days of storage Volume required for 4 days storage = (24 x 4 x 650) / 700 = 89.14 m3 Say = 90 m3 Assuming stacking height as 2 meter maximum Dimension of the storage room required is 15 X 3 X 2 meter

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3. Steam Cost The cost of fuel / kg of steam = 3.5 / ((3700 / 540) X 0.68) = 0.76 Rs/Kg of steam Assuming cost of power = 0.1 Rs/kg Manpower cost = 0.03 Rs/Kg Total cost of steam = 0.76 + 0.1 + 0.03 = 0.89 Rs/Kg Say= 0.9 Rs/Kg 08.1 Conclusion: Expected Savings From above calculations it is clear that cost of steam by solid fuel boiler will be much cheaper then FO fired non IBR boilers. Minimum 50% savings can be achieved by replacing four 850 Kg/hr FO fired non IBR boiler by one single 3 T/hr solid fuel IBR steam boiler. It will be beneficial to go for 1 IBR boiler instead of running 4 non IBR boilers. Present Steam cost = 2.5 Rs/ Kg of steam Expected Steam Cost = 0.9 Rs / Kg of steam Savings on per Kg steam = 2.5 0.9 =1.6 Rs Or Say minimum 1.25Rs/kg Average Steam consumption of both the plants = 1700 Kg/hr Or 1700 x 20hr x 30days = 10,20,000Kg / month Average minimum savings will be = 1.25 x 10,20,000 = 12,75,000 Rs / month Or = 12 x 12,75,000 = 1,53,00,000 / Annum.

Say

= 1,50,00,000 / Annum.

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08.2 Payback calculation: Investment on new soild fuel boiler is given below in table; Sl No. 1 2 3 4 5 6 7 Description Boiler Turnkey Project Civil Work (Shed & Foundation) Soft water Piping & Pump Soft Water storage tank Contingencies SubTotal-01 Interest @ 12% Depreciation 10% SubTotal-02 Grand Total Payback = 44.34 / 150 = 0.3 Year = 3.6 months Cost (Lacs) 26.75 5 2.5 0.6 1.5 36.35 4.36 3.63 7.99 44.34 Remark

= Say 4 months
09. Land requirement & Selection: Requirement of land including solid fuel storage area, Chimney, MDC, Boiler, air preheater unit, ID fan, FD fan, blow down pit, soft water storage tank and feed water tank will be near about 400 M2. Land should be far from process area as a safety point of view. To cope-up with above requirement only suitable place is Shashank Block which is in the middle of the both process units. Free land area behind maintenance workshop is near about 768 M2 (32 Mtr x 24 Mtr), which can be utilized very effectively for above requirement. 10. Layout plan for new 3T steam Boiler: Layout plan for new boiler is given below:

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Propsed layout Plan of 3 T Steam Boiler at Shashank Block
14.4 9.3 Vaccant Space 9.3 X 1.5 APH: 1.5 X 1.5 MDC: 1.5 X 1.5 IDF: 0.8 X 1.5 Chimeny Foundation N

Unit- Mtr
2.4 2.7

7.3
Column: 2X 0.4 Column: 2X 0.4

Vaccant Space: 1.5 X 9.0

Furnace : 2.9 X 3.0

Shell : 4.0 X 1.6

Side Space: 2.7 X 11.0

Pathway to Storage :2.4 X 13.4

Firing 3.7 Office Space: 2.0 X 2.0

Column -0.3 x 0.3 Boiler House: 10.30 X 9.30 Pathway to Storage :2.4 X 11.7 23.8

13.4 11.7

Soft Water Storage Tank-10 KL

1x0.4

Pump

Fuel Storage :2.7 X 16.5

Green Area 11.7 X 10.4

Future Ezpansion for Fuel storage : 2.80 X 10.40

PED/AAD/RAM/18.07.08

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Quotations for 3T steam boiler: For new 3T solid fuel steam boiler weve got three different quotations from three parties M/s Forbes Marshall, M/s Thermax and M/s Micro Tech Boilers. Here M/s Thermax has submitted their quote for conversion of existing 4 T FO fired boiler to solid fuel boiler at Harpanhalli unit, while others have given their quote for new 3 T solid fuel steam boilers. The amounts theyve quoted are 70 Lacs for M/s Forbes Marshall, 34 Lac s for M/s Thermax and 29 Lacs for M/s Micro Tech Boilers. Most effective quote for 3T boiler is from M/s Forbes Marshall because of benefit of their Energy audit at KOPL & detailed study report submitted by them.
11. Comparison report for 3T Steam Boiler:

Three quotations are received for 3T steam boiler, a brief comparison report for them are given below

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13. Schematic diagram of 3 T Solid Fuel Boiler

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As its clear from above comparison among three parties that M/s Micro tech Boilers have given the most competitive quote as point of price. After discussions with their existing customers like Mr. Gautam Chaudhary (MD M/s Santosh Maize & India Ltd), boiler performance report is found satisfactory. Finally the order for new 3 T Steam boiler is given to M/s Microtech Boilers. A schematic diagram of the solid fuel boiler is given below Finally whole Turn-Key project is given to M/s Micro tech Boilers for 26.75 Lacs inclusive of all taxes. 13. Schematic diagram of 3 T Solid Fuel Boiler

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14. Other details of new 3 T Steam Boiler: Following points to be consider for new boiler. 14.1 Feed Water details:
a. Feed water requirement for the boiler is 3m3/hr and it will be process at same

existing Soft water & RO plant at Shaureya block.

b. Capacity of RO plant Shaureya Block is 4.5 M3/hr. c. As distance between new boiler house to soft water plane will be 200-225 mtr. d. Specification of final discharge pumps at Soft water plant is Head-35 Mtr &

Flow- 4 M3/hr which is sufficient to pump the feed water to the boiler house.
e. For supply of feed water combination of two storage tanks of capacity 5 KL

& 10 KL will be utilized.

f. One 10 KL storage tank will be kept at boiler house on the ground which will

be flooded by soft water plant. From this 10 KL storage tank water will be pumped to 5 KL storage tank.
g. Existing 5 KL storage tank of soft water plant will be kept on the top of the

proposed boiler house (existing Building) for Boiler feeding. 14.2 Layout & Sizing of pipe line: a. In boiler house two headers shall be made i.e. High Pressure & Low Pressure. b. From HP header to LP header steam will be supplied through one PRS station. c. From HP header two lines will go to Jigani Unit & Shaureya Block (Jappro unit) of 65NB/50NB. d. For Jigani plant after Jappro unit line will be converted to 80NB LP line by using one PRS station. e. From LP header two lines of 40NB/80NB will go to pilot plant & Shaureya block.

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Jigani & Shaureya Plant New Boiler piping Layout

Scale 01mm = 01 Mtr Jigani Unit

LP
26

HP
40 20

Pilot Plant

2 8 50 26

03MT Boiler

Shashank Block
60

N
Solvent Tanks
24

Shaureya Block

64

LP

HP

18.07.08/AAD/RAM

Process Engineering Department

14.3

Chimney dismantling & Fixing: a. Chimney dismantling from Harpanhalli unit, shifting & fixing for new 3T Steam boiler. b. Chimney dismantling from Shaureya Block incinerator, shifting & fixing at Harpanhalli boiler.

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