KOHINOOR CHEMICAL CO (BD) LIMITED

A Walk Through Energy Efficiency in SMEs by Bangladesh APO E-Learning Team

Date: May 20, 2010
Field Visit: Kohinoor Chemical CO
(BD) Limited

Kohinoor Chemical CO (BD) Limited .

Bangladesh Team May 20 2010

 Brief Histology of the
Factory
1956
Project was established in Private Sector as a leading Cosmetics
and Toiletries in PAKISTAN

1972
Government of Bangladesh Nationalized the factory under
Bangladesh Chemical Industries Corporation

1993
Government of Bangladesh handed over the factory again to the
Private sector.
At Present the factory is producing the Cosmetic and Toiletries product under the
different Brand name as a sister concern of Orion Group
 Factory Overview

Factory Data Product Data

 Location: Dhaka, Bangladesh Major Products:
 Country of Origin of Plant & Facial cream, pumpkin oil, shaving
Machineries: UK, Pakistan, USA cream, washing soap, Toilet soap,
 Employees: 1010 detergent, toothpaste
 Project Areas: 12.29 Hectors
Detergent
 Operation: 24 Hours-365 days Pow der, 15%

Shaving Washing Soap,

 Raw Materials Used Cream , 3% 25%
Hair Oil, 2%
 Steric Acid, Pumkin, Caustic Tooth Paste,
Soda, Fat, chemicals and 5%
fragrance.

Toilet soap,
50%

Total Production: 31037 ton/yr

 Process Diagram For
St. Acid [112 kg],
ToothpasteSorbitol [23 kg], Glycerin
KOH [40.5 kg] , RBD [32 kg] , St. Acid [16 kg],
[60 kg] Perfume [7.5 kg]
4 hrs 30
mins
Steam heating
 Major Energy Consuming
Units
Plant/Section Energy Consuming Form of
Equipment Energy
Steam Boiler Gas
Generation
Diesel Diesel Engine Diesel
Generator
Gas Generator Gas Engine Natural Gas
Compressor Blower/Motor Electrical
Power Gas Engine Gas
Generation
Digester Steam Heater, Electric Steam,
Heater Electricity
Mixer Electricity Electricity
Air Conditioning Air Conditioner, Fan Electricity
Energy Distribution
Diagram
Gas Turbine: 900 KW
Total 1300 KW
Govt. Power: 400 KW

Fat melting
Generator 1% Glycerin Plant
4%
1%
Detergent Factory
Pump
10%
10%
Boiler
2%

Normal and
Washing Saop
Cosmetics 34%
21%

Beauty Saop
17%
Steam Distribution Diagram

10 ton/hr

NG
Boiler

Main Steam Header

15 Kg/cm2

Soap Cosmetic Soap

Digesting Section Manufacturing
6 ton/hr 2 ton/hr 2 ton/hr

Condensate
to Drain out
 Schematic Diagram of Existing Boiler

STEAM TO EXHAUST
PROCESS GAS VENT

Natural Circulation type

water tube boiler STACK
DEAERATOR
1983: Installation
Rated capacity: 10 ton/hr Storage
tank
Rated pressure: 15 kg/cm2 Boiler Feed
Water Pump
BOILER
PAKISTAN
HMC BURNER
WATER
BLOW DOWN
FROM MUD Blower SOURCE
DRUM
FUEL

BRINE
CHEMICAL FEED
SOFTENERS
Deep well turbine pump
 General Information About Existing
Boiler

 Existing Boiler Efficiency : 72% (Calculated)

 Fuel Consumption rate : 906 Nm3/hr (NG)
 Gas Consumption/ton of steam : 90.6 Nm3
 Cost/ton of steam (Fuel) : BDT 530
: USD 7.6
 Scope of Intervention
STEAM TO EXHAUST
GAS
PROCESS
VENT

STACK

Condensate
DEAERATOR
From
Preheater Process
Storage
Blower tank
Boiler Feed
Economizer Water Pump
BOILER
PAKISTAN
HMC BURNER
WATER
SOURCE

FUEL

BLOW DOWN
FROM MUD BRINE
DRUM
CHEMICAL FEED
SOFTENERS
Deep well turbine pump
 Condition of Boiler after Intervention

 Expected Boiler Efficiency : 81%

 Expected Fuel Savings/year : 32,507 Nm3 (NG)
 Annual equivalent cost savings : BDT 190462
: USD 2721

We observed that 9 ton/hr condensate is being drained

 450000 kcal/hr heat can be recovered from the condensate
recovery
 Equivalent fuel savings : 478483 Nm3/year
 Equivalent annual financial savings : BDT 2803912
: USD 40059
Recommendation
 Maintain proper air-fuel ratio for
combustion by controlling air damper.
 Maintain regular tube cleaning and boiler
feed water treatment.
 Install air pre-heater and economizer.
 Insulate all steam bare pipes and flanges.
 Stop all steam leakages.
 Ensure functioning of steam traps.
Damaged and Without
Insulation
Group Members - Group 1
eLearning Course on Energy Efficiency
in SMEs
 Engr. S.M. Mahmud Hassan - Team Coordinator
 Engr. Horendro Nath Ghosh – Team Leader
 Engr. Kaisar Ahmad Bhuyan
 Engr. Md. Hanif Sarkar
 Engr. Muhammd Rakibul Islam
 Engr. Md. Rafiqul Islam
 Engr. Md. Abdur Rouf Khan
 Engr. Mohammad Abdul Mannan
 Engr. Md. Mokdum Ali
 Engr. Zakia Afroz
 Engr. Md. Mehedi Hasan
 Engr. Mriganka Mohan Paul
 Engr. Didarul Islam