Asian Paints Limited Penta Division Cuddalore

EXCELLENCE IN ENERGY
MANAGEMENT
BY
ASIAN PAINTS LTD.
PENTA DIVISION, CUDDALORE.
ABOUT US
Asian Paints is Indias largest Paint Company and ranked among
the Top 10 decorative coating companies in the World.
We have 28 Manufacturing facilities across the World servicing
Consumers in 65 Countries.
In India, we have 9 plants manufacturing coatings and 2 plants
manufacturing chemicals. Our Unit manufacturing Pentaerythritol
is located at Cuddalore, Tamilnadu.
Penta Division is accredited with ISO 14001 and OHSAS 18001
certification and manufacturers following chemicals :
Various grades of Pentaerythritol
Sodium Formate
Formaldehyde
We have an enviable reputation for innovative Energy conservation
practices which helped us to bring down the specific energy
consumption, helping the division survive.
PROCESS
Involves precisely controlled Reaction of Formaldehyde
and Acetaldehyde in the presence of Caustic soda.
The product of the Reactor is concentrated by Evaporation
followed by Crystallization and separation in a Vacuum
belt filter.
The product of Vacuum belt filter is purified, dried and sent
for packing.
PROCESS BLOCK DIAGRAM

Fa
Aa
Reaction
Ca
For Formaldehyde
and
Methanol Recovery
Knock
Down
Tank
Crude
Vacuum
Crystalliser
Five Effect
Evaporator
Stripper
Crude Belt
Filter
Deionizer /
Carbon
columns
Distillation
Column
Crude Mother Liquor

TO AIR
Crystalliser
Pure
Vacuum
Crystallizer
Tech PE
Drier
Tech PE
Silo
Tech PE
Bagging
TO AIR
Sodium
Formate
Drier
TO AIR
Tech
Dissolver
Crystalliser
Mech
Sieving
Mono PE
Drier
Mono PE
Silo
Mono PE
Bagging
TO AIR
PE : Pentaerythritol
Di PE
Drier
Di PE
Silo
Di PE
Bagging
Sodium
Formate
Bagging
ENERGY COSTING
Energy Cost accounts for 19% of the total manufacturing cost and
48% of the plant overheads in FY 2011-12.
Working towards
achieving zero
grid power
consumption
Electrical Energy Cost

Thermal Energy Cost
100
80
5.9
4.8
24.4
60
40
94.1
95.2
2010-11
2011-12
75.6
20
0
2009-10
The Co-Gen system generates

required Electrical energy.
Cost of imported Energy from
the grid alone is captured as
Electrical energy cost.
ENERGY CONSERVATION ACTIVITIES 2009 to 2012

Sl.
No.
1.
2.
3.
4.
Activity (2009-10)
Investmen
t (RL)
Reduction in
specific
steam
consumption
in MT/TPE
Reduction in
specific
power
consumption
in kwhr /TPE
Power
savings
per annum
(Units in
Lacs)
Fuel (COAL
of 6000 kcal)
Saving per
annum (MT)
Cost Saving
Per annum
(RL)
Saving as %
of energy bill
Replacing Crude Belt Filter

(CBF) Vacuum pump with
Energy efficient pump
1.1
---
15.4
0.73
---
3.27
Replacing Pure Belt Filter

(PBF) Vacuum pump with
Energy efficient pump
0.96
Replacing the low pressure

Boiler of 20.5 KSC Pressure,
14 TPH capacity and low
Efficiency Turbine with high
pressure Boiler of 45 KSC
Pressure and High Efficiency
Turbine to increase the power
generation from the Back
pressure Turbo Alternator for
the same Steam flow.
749
Reducing 1500 KVA Turbo

Alternator frequency from 50
Hz to 48.5 Hz
0.41 %
---
13.7
0.65
---
2.9
0.37 %
---
---
36.29
---
163.3
20.6 %
---
108.4
5.09
---
22.93
2.9 %
Contd . . .
S.No
Activity (2009-10)
Investment
(RL)
Reduction in
specific
steam
consumption
in MT/TPE
Reduction in
specific
power
consumption
in kwhr /TPE
Power
savings
per annum
(Units in
Lacs)
Fuel (COAL
of 6000 kcal)
Saving per
annum (MT)
Cost Saving
Per annum
(RL)
Saving as %
of energy bill
5.
Increasing the
production/Rxn. by
Increasing the Initial
Formaldehyde concentration
from 10.1 to 10.5 leading to
reduction in energy
consumption (Reduction in
water input into the process)
---
10.29
0.48
---
2.18
Replacement of Pressure
Reducing Station (PRV for
45 to 5.2 KSC) with Thermo
compressor for increasing
power generation through
turbine. (Even though this
activity has resulted in an
additional power generation
of 168 KW which is around
15% of our total power
consumption, the same will
not get reflected in Specific
energy consumption)
7.0
Firing of Waste gas

containing Hydrogen and
traces of methanol from
Formaldehyde plant in boiler
for generating steam
1.6
Installation of 2Nos of 18.5

KW VFD for Cooling Tower
Fan application.
1.6
6.
7.
8.
2.7 %
---
---
13.55
---
60.96
7.67 %
---
---
---
961
45.17
5.69 %
---
15.44
0.73
---
Contd . . .
3.99
0.5 %
Sl.
No
Activity (2010-11)
Investment
(RL)
Reduction in
specific
steam
consumption
in MT/TPE
Reduction in
specific
power
consumption
in kwhr /TPE
Power
savings
per annum
(Units in
Lacs)
Fuel (COAL
of 6000 kcal)
Saving per
annum (MT)
Cost Saving
Per annum
(RL)
Saving as %
of energy bill
9.
Reducing Cooling Water

circulation flow rate by replacing 3
Nos. of Shell and Tube Heat
Exchangers with a single PHE in
distillate line going to Reactor.
3.75
0.037
19.4
1.05
32.63
6.29
Optimization of Batch cycle time in

Vacuum Crystallizer by Removing
the Cyclone separator which was
a part of imported crystallizer.
Increasing the Power throughput

across the Turbo Alternator (Back
pressure Turbine) by increasing
the steam drawn through the
Turbine and simultaneously
reducing the HP steam
consumption which is bypassing
the turbine. The medium pressure
requirement is reduced from 5.2 to
4.8 KSC by increasing the Heat
transfer area of the Re-boiler.
However the overall steam
consumption remains the same.
(Even though this activity has
resulted in an additional Power
Generation of 41.25 KW, the same
will not get reflected in Specific
Power consumption. Indirectly the
power drawn from the TNEB grid
has reduced to that extent.)
4.62
10.
11.
0.68 %
0.202
---
---
176.8
8.48
0.92 %
---
---
3.33
5.8
14.97
1.63 %
Contd . . .
Sl.
No
12.
13.
14.
Activity (2010-11)
Investment
(RL)
Reduction in
specific
steam
consumption
in MT/TPE
Reduction in
specific
power
consumption
in kwhr /TPE
Power
savings
per annum
(Units in
Lacs)
Fuel (COAL
of 6000 kcal)
Saving per
annum (MT)
Cost Saving
Per annum
(RL)
Saving as %
of energy bill
Replacing 150 W, HPSV

Street light fittings with LED
fittings of 30W (10 Nos)
0.95
---
1.05
0.06
---
0.26
Replacing Electric storage

Water heaters with Solar
water heater in canteen
application.
2.2
Installation of a Boiler steam

Air pre-heater in order to
balance the plants thermal
energy and Electrical energy
requirement for efficient
operation of Cogeneration
system. This activity resulted
in elimination of steam
venting on account of
mismatch between thermal
and Electrical energy
requirements of the plant.
2.5
0.03%
---
4.87
0.26
---
1.18
0.13 %
---
---
---
552
28.69
3.1 %
Contd . . .
Sl.
No
Activity (2011-12)
Investment
(RL)
Reduction in
specific
steam
consumption
in MT/TPE
Reduction in
specific
power
consumption
in kwhr /TPE
Power
savings
per annum
(Units in
Lacs)
15
Reducing the plant operation

days per month from 28.08
days to 26.75 days for
achieving the consented
production of 450 MT/month
by1. Optimising the reaction
batch cycle time from 45 min
to 40 min by increasing the
reactant flow rate without
affecting the reaction
performance.2. Reducing the
batch cycle time of T148
(Tech dissolver) by 15 min. by
simultaneous pumping of its
feed streams.
0.0
---
57.99
3.13
Reducing the steam

consumption in
Formaldehyde plant by
optimizing the conversion of
Methanol to Formaldehyde in
Reactor by reducing the
concentration of feed
methanol.
0.0
Reducing the water ingress

into the process by
automation of Crude Belt
Filter cake wash.
0.9
16
17
Fuel (COAL
of 6000 kcal)
Saving per
annum (MT)
Cost Saving
Per annum
(RL)
Saving as %
of energy bill
14.09
1.4 %
0.299
---
--
261.1
13.86
1.4 %
0.179
---
---
155.64
8.32
0.83 %
Contd . . .
Sl.
No
18
19
20
21
Investment
(RL)
Reduction in
specific
steam
consumption
in MT/TPE
Reduction in
specific
power
consumption
in kwhr /TPE
Power
savings
per annum
(Units in
Lacs)
Fuel (COAL
of 6000 kcal)
Saving per
annum (MT)
Cost Saving
Per annum
(RL)
Saving as %
of energy bill
Reducing Power consumption

of Lobe blower for conveying
Off gas from Formaldehyde
plant to Boiler by reducing the
pressure drop across the line.
2.75
--
16.43
0.89
--
3.99
Increasing the Power

generation per MT of steam
across the TG (Turbo Generator) by reducing the
pressure drop across the
governor valve. (By way of
widening the governor opening
limits)
0.0
Reducing the Power

consumption in ETP aerator by
providing VFD with necessary
speed control system based on
COD level in aerator.
0.9
Replacing 150 W, HPSV Street

light fittings with LED fittings of
45W (10 Nos)
0.99
Other miscellaneous projects

over the past three years
(14 projects)
8.76
5.13
108.2
39.14
3.86%
789.6
77.49
2062
460.8
Activity (2011-12)
TOTAL
0.4 %
---
---
1.51
---
6.8
0.69 %
---
4.87
0.26
---
1.18
0.12 %
---
0.93
0.05
---
0.23
0.02 %
29.2 %
17%
Sl.
No
18
19
20
21
Investment
(RL)
Reduction in
specific
steam
consumption
in MT/TPE
Reduction in
specific
power
consumption
in kwhr /TPE
Power
savings
per annum
(Units in
Lacs)
Fuel (COAL
of 6000 kcal)
Saving per
annum (MT)
Cost Saving
Per annum
(RL)
Saving as %
of energy bill
Reducing Power consumption

of Lobe blower for conveying
Off gas from Formaldehyde
plant to Boiler by reducing the
pressure drop across the line.
2.75
--
16.43
0.89
--
3.99
Increasing the Power

generation per MT of steam
across the TG (Turbo Generator) by reducing the
pressure drop across the
governor valve. (By way of
widening the governor opening
limits)
0.0
Reducing the Power

consumption in ETP aerator by
providing VFD with necessary
speed control system based on
COD level in aerator.
0.9
Replacing 150 W, HPSV Street

light fittings with LED fittings of
45W (10 Nos)
0.99
Other miscellaneous projects

over the past three years (14
Nos.)
8.76
5.13
108.2
39.14
3.86%
789.6
77.49
2062
460.8
Activity (2011-12)
TOTAL
0.4 %
---
---
1.51
---
6.8
IRR 28.1%
0.69 %
---
4.87
0.26
---
1.18
0.12 %
---
0.93
0.05
---
0.23
0.02 %
29.2 %
17%
INTERNATIONAL NORMS VIS--VIS OUR PERFORMANCE

NORMS**
ACTUALS 2011-12
PERFORMANCE
Specific Steam
consumption (MT)
20
19.56
2.2 %
Specific Power
consumption (Kwhr)
2200
1363
38 %
** Norms specified by the Technology provider M/s.Hercules Inc.,USA.
IMPACT ON SPECIFIC POWER / STEAM CONSUMPTION

Details
Steam Consumption
in MT
Power Consumption
in Kwhr
Specific consumption
during 1999
25.03
2643
Specific consumption
during 2011-12
19.56
1363
A whopping reduction of
22 % in Steam Consumption
48 % in Power Consumption
TREND- SPECIFIC POWER CONSUMPTION

3000
2800
2600
2850
2750
2694
2643
2400
2400
2200
2000
1800
1600
1400
2400
2431
2200
2150
1975
2090
1929
1825
1650
1695
1550 1550 1540 1540
1587
1554 1548 1521
1489
1510
1450
1380
1421 1391
1363
1200
96-97 97-98 98-99 99-00 00-01 01-02 02-03 03-04 04-05 05-06 06-07 07-08 08-09 09-10 10-11 11-12
ACTUALS
2850 2694 2643 2431 2200 2090 1929 1695 1587 1554 1548 1521 1489 1421 1391 1363
TARGETS
2750 2400 2400 2150 1975 1825 1650 1550 1550 1540 1540 1510 1450 1380
A whopping reduction of 52% in Power Consumption
TREND- SPECIFIC POWER CONSUMPTION
1550
1500
1510
1450
1450
1400
1421
1391
1350
1380
Target
Actual
1363
1300
1250
2009-10
2010-11
2011-12
TREND - SPECIFIC STEAM CONSUMPTION

36
36.00
34.00
33.30
32.00
34
32
30.30
30
30.00
27.80
27.25
29
28.00
26.00
27
28
25.03
27
26
23.37
24.00
24
22.00
24
21.04
22.75
19.81 19.56
19.20 19.25 19.00 19.08

19.18 19.10
21
20.75
20
20
20
19.5 19.8 19.6
18.35
20.00
18.00
16.00
22
20.01
9697
9798
9899
9900
0001
0102
0203
0304
0405
0506
0607
0708
0809
0910
1011
1112
ACTUALS 33.30 30.30 27.80 27.25 25.03 23.37 21.04 19.18 19.10 20.01 19.20 19.25 19.00 19.08 19.81 19.6
TARGETS
29
27
27
24
22.8 20.8 18.4
21
20
20
20
19.5 19.8 19.6
A whopping reduction of 41.3 % in Steam Consumption
20
18
16
TREND - SPECIFIC STEAM CONSUMPTION

20
19.5
19
19.8 19.81
19.5
19.6 19.56
19.05
18.5
18
17.5
17
18.8
18.6
2010-11
2011-12
16.5
16
15.5
15
2009-10
We have commissioned a Zero liquid Discharge system

comprising of Multiple Effect Evaporator and ATFD leading to
increase in Steam consumption.
Target
Actual
PROCESS BLOCK DIAGRAM

Fa
Aa
Reaction
Ca
For Formaldehyde
and
Methanol Recovery
Knock
Down
Tank
Crude
Vacuum
Crystalliser
Five Effect
Evaporator
Stripper
Crude Belt
Filter
Deionizer /
Carbon
columns
Distillation
Column
Crude Mother Liquor

TO AIR
Pure
Vacuum
Crystallizer
Crystalliser
Bottlenecks
Tech PE
Drier
Tech PE
Silo
Tech PE
Bagging
TO AIR
Sodium
Formate
Drier
TO AIR
Tech
Dissolver
Crystalliser
Mech
Sieving
Mono PE
Drier
Mono PE
Silo
Mono PE
Bagging
TO AIR
PE : Pentaerythritol
Di PE
Drier
Di PE
Silo
Di PE
Bagging
Sodium
Formate
Bagging
Innovative project 1
Reducing the Plant operating days by optimizing the
cycle time of Batch operations.
Concepts :
Increasing the Reaction batches/day by optimizing the Reaction
Batch cycle time.
Increasing the Mono Pentaerythritol (PE) batches/day by optimizing
the processing time.
System:
The process of manufacturing of PE starts with a batch reaction
involving Formaldehyde, Acetaldehyde and Caustic solutions. By
optimizing the batch cycle time of reaction, we could increase the
reaction batches/day, thereby reducing the number of plant operating
days.
In the manufacturing of Mono PE the batch cycle time of Batch
evaporation was optimized by which the number of batches/day was
increased.
Activity (A). Optimization of Reaction time:
Conducted Pilot reactor studies.
Sample output analyzed every 5 minutes and compared with
standards.
By increasing the rate of addition of the reactants to the
Reactor without affecting the kinetics of the reaction, the Reaction
batch cycle time was reduced by 5 minutes per reaction
(Reaction time has got reduced to 40 minutes from 45 minutes).
Necessary controls exercised to prevent the side reactions.
Exothermic reaction was controlled by adequate cooling.
After successful implementation of this project, average Reaction
batches per day got increased to 18.5 from 17.5.
Duration
in minutes
Before
CW O/L
Acetaldehyde
Caustic
Formaldehyde
Chilled water
to PHE
10
Cooling water
to PHE
35
CW I/L
CHW O/L
CHW I/L
Reaction Time
45 Mins
Reactor
P101
Duration
in minutes
After
CW O/L
Acetaldehyde
Caustic
Formaldehyde
Chilled water
to PHE
15
Cooling water
to PHE
25
CW I/L
CHW O/L
CHW I/L
Reaction
Time 40 Mins
Reactor
P101
Activity (A): Optimization of Reaction Batch cycle time
Before
After
Reaction time
45 min.
40 min.
Reaction batches per day
17.64
18.54
Penta Production per day
16.03 MT
16.82 Mt
Consented Limit
450 MT/month
450 MT/month
No of days of Operation
28.08 days
26.75 days
Activity (B). Optimization of Batch evaporation:
By implementing the system of simultaneous pumping of two feed
streams for evaporation, the batch evaporation cycle time has got
reduced by 30 minutes per batch, because of which the number of
batches per day has got increased.
Flow meters with integrators were installed in both feed streams in
which the required quantity of feed were set and batch pumping
was done in auto mode because of which the time delay due to
manual pumping of two streams one by one was eliminated
completely.
Before
80%
Total Filling
Time 55mins
50%
Tech
Dissolver
20%
Pumping
Time 30mins
Pure Penta Solution
Pumping
Time 25mins
Recycled Penta Solution
After
80%
FIT
FIT
Total Filling
Time 30 mins
Tech
Dissolver
Pure Penta Solution
20%
Recycled Penta Solution
Activity (B): Optimization of Tech dissolver batch cycle time
Before
After
Feed streams pumping time
55 min
30 min
Tech Dissolver Batches per

day
4.17
4.50
Batch Cycle time
350 minutes
325 minutes
Penta Production per day
16.03 MT
16.82 Mt
Consented Limit
450 MT/month
450 MT/month
No of days of Operation
28.08 days
26.75 days
After
After successful implementation of these projects, the reaction batch
cycle time has got reduced by 5 minutes per reaction and the batch
evaporation cycle time has got reduced by 25 minutes per batch, resulting
in decreased plant operating days from 28.08 days to 26.75 days.
Average power consumption/month before implementation: 625902 KWHr
Average power consumption/month after implementation : 599808 KWHr
Reduction in Specific Power consumption 58 KWHr/TPE (4% reduction)
Power savings achieved:
Power savings achieved per year
Cost savings achieved per year
: 3.13 Lac units

: 14.09 RL
After
After successful implementation of these projects, the reaction batch
cycle time has got reduced by 5 minutes per reaction and the batch
evaporation cycle time has got reduced by 25 minutes per batch, resulting
in decreased plant operating days from 28.08 days to 26.75 days.
Average power consumption/month before implementation: 625902 KWHr
Average power consumption/month after implementation : 599808 KWHr
Reduction in Specific Power consumption 58 KWHr/TPE (4% reduction)
Power savings achieved: This project gave scope to
seek expansion for Capex
Presently
Power savings achieved enhancement.
per year
: 3.13
Lac units
EC awaited
from
MoEF
Cost savings achieved per
year
: 14.09
RL for
24% increase in
production capacity
Reducing the steam consumption by optimizing the
conversion of Methanol to Formaldehyde in Reactor by
reducing the concentration of feed methanol.
Objective :
To reduce the excessive steam consumption in the Re-boiler of
Distillation column of Formaldehyde plant by reducing the methanol
% fed to Distillation column.
System :
Formaldehyde is produced by partial oxidation of methanol over silver
catalyst.
Air methanol as per ratio is produced in a carburetor and passed over
a silver catalyst to produce formaldehyde. The vapor outlet of reactor
is absorbed through DM water.
Feed methanol concentration is maintained at 84% so as to have
excess methanol mixture fed to the reactor.
The liquid mixture containing formaldehyde and unreacted methanol
is distilled in Dist. Column. Methanol is recycled back to the system.
Steam consumption in Distillation column is proportional to the feed
Methanol %.
Activity:
Feed Methanol concentration to Carburetor was reduced from 84% to
68% keeping air constant.
Methanol fed to reactor reduced leading to less methanol % at the
outlet of reactor.
Steam consumption in Distillation column got reduced due to reduced
feed Methanol %.
Before :
Recycle
methanol to
carburetor @
600 kg/hr
DM
water@
650 kg/hr
Air
Carburetor
2000
Kg/hr
Reactor
Absorber
Distillation
Column
3100
Kg/hr
84 %Methanol
1850 Kg/hr
2000 kg/ hr
Steam
37 % Fa product
@ 2500 Kg/hr
Recycle
methanol to
carburetor @
500 kg/hr
After :
DM
water@
500 kg/hr
Air
Carburetor
Reactor
Absorber
Distillation
Column
3000
Kg/hr
2000
Kg/hr
68 %Methanol
2000 Kg/hr
1800 kg/ hr
Steam
37 % Fa product
@ 2500 Kg/hr
Advantages
Before
After
1 Methanol Feed concentration
84%
68%
2 Reactor conversion efficiency
60%
70%
3 Unreacted Methanol fed to

Distillation column
19%
13%
2000 Kg/hr
1800 Kg/hr
4 Steam to Distillation Column

Re-boiler
Reducing the water ingress into the process by
automation of Crude Belt Filter cake wash.
Objective:
To eliminate the fluctuations in CAC wash water fed to Crude
vacuum belt filter (CBF) by automation of wash system.
System :
Crystallized Pentaerythritol (PE) along with Sodium formate (SF) in
dissolved state is fed continuously to a vacuum belt filter to separate
the PE as cake and SF as mother liquor.
The rate of CAC wash determines the purity of PE cake (free from
SF contamination).
CAC wash rate is controlled manually by monitoring the flow through
Rotameter.
Reducing the water ingress into the process by automation of
Crude Belt Filter cake wash.
CAC Wash Header
Before :
Rotameter
Recycled wash
Feed to CBF
S 170
Feed
Tank
T 119
T17
02
ML
P 170-1
P 170-2
PE
cake
T 171
T17
03
P 170-3
Spent wash liquor to Evaporator

ML to SF section
Constraints faced:
CAC wash elsewhere in certain batch operation in the plant leads to
pressure fluctuations in the CAC header leading to flow fluctuations
in CBF.
Additional wash requires additional Re-evaporation.
Production capability reduction.
Reducing the water ingress into the process by automation of
Crude Belt Filter cake wash.
CAC Wash Header
FIC
After :
Recycled Wash
MF
Feed to CBF
S 170
Feed
Tank
T 119
T17
02
ML
P 170-1
P 170-2
PE
cake
T 171
T17
03
P 170-3
Spent wash liquor to Evaporator

ML to SF section
1 Average CAC wash rate.

2 Steam consumption for
Re-evaporation
Before
After
12 lpm
10 lpm
720 Kg/hr
600 kg/hr
Advantages:
Steam savings to the tune of 968 Tons/annum
Consistent cake purity leading to better process stability.
Production capability increased by 1.3%
ENVIRONMENTAL IMPROVEMENT PROJECTS

Installed Methanol and Formaldehyde storage tanks vent collection and
recycling system at a cost of 11.7 RL to eliminate VOC emissions
through tank breathing.
Installed a over head spray nozzles in the ash yard to ensure complete
suppression of dust at a cost of 4.5 RL. This is in light of the recent
CPCBs recommendations of PM 2.5
Installation of Sophisticated Dust Collecting System to keep the Boiler
stack emission SPM levels to less than 50 mg/Nm3.
Contd . . .

We have installed a RO system followed by MEE and ATFD to become a
Zero liquid discharge unit with respect to liquid effluent. We recycle
almost 90% of the effluent generated. Project cost: 1.3 Cr
We have implemented LDAR system to track fugitive and point source
emissions. Project cost: 4.2 RL
Installation of Rupture disc at upstream of Acetaldehyde bullet safety
valves. Project cost: 4.3 RL
We have developed Green Belt over more than 45% of the total factory
area.
Contd . . .
We have replaced the asbestos top roofs of our coal yard and boiler
areas which were got damaged during Thane cyclone with environment
friendly Powder coated metal sheets.
Before
After
Contd . . .

Online VOC meters were procured for
monitoring the presence of VOC in
process stacks and Ejectors.
Portable VOC analyzer was
purchased. LDAR study was done
internally and by external laboratories
like M/s. SGS lab, Chennai. VOC
emissions are on lower side.
We have installed the Weather
monitoring station in our plant and the
parameters are being monitored on
continuous basis.
Contd . . .
RAIN WATER HARVESTING AT SITE
Contd . . .
Tree plantation
By our Chairman
By ISO Auditors
By DEE, TNPCB
By Employees
ENERGY MONITORING FORMAT & METHODOLOGY

THERMAL ENERGY :
Total Steam flow from the boiler to the plant is measured using
Pressure & Temperature Compensated Vortex Steam Flow meter.
Steam flow measurement systems are available for measuring

individual flow to various sections of the plant.
Steam balance is carried out on daily basis and any increase /

decrease in steam consumption vis a vis production is adequately
reasoned out.
Yearly steam audit by external competent agency
Steam trap monitoring by external agency

Daily monitoring format Thermal Energy
April 2012
DATE
Steam Generation MT
SH Steam MT
Water Consumption kL
Vented Steam
SAT Steam MT DSH Steam MT MT
Hot Cond
Power gen. kW-hr
Penta Steam
MT
DM Water
Water - Steam
TG
Balance
EB Cons kW-hr
DG
Power / MT
Steam
Stock on hand
MT (06:00 hrs)
Coal Receipt Coal Consump.

MT
MT
Penta Prod
MT
01-04-2012
0.00
0.00
0.00
0.00
0.00
50.00
0.00
-50.00
2760
#DIV/0!
581.67
0.00
0.00
02-04-2012
0.00
0.00
0.00
0.00
0.00
18.00
0.00
-18.00
3540
#DIV/0!
581.67
0.00
20.00
03-04-2012
227.00
24.50
15.70
2.90
131.00
181.00
251.50
-44.80
13550
1628
32
59.69
581.67
118.03
50.0
20.00
04-04-2012
277.00
38.00
19.40
0.80
248.00
54.00
315.00
32.40
19700
100
71.12
649.70
0.00
61.0
32.50
05-04-2012
287.00
39.90
20.00
0.10
270.00
55.00
326.90
21.90
20750
52
72.30
588.70
0.00
63.4
12.00
06-04-2012
289.00
42.40
20.20
0.00
271.00
53.00
331.40
27.60
21670
60
74.98
525.30
53.33
64.0
15.75
07-04-2012
290.00
43.00
20.20
0.20
265.00
55.00
333.00
33.20
21800
75.17
514.63
116.92
64.6
14.75
08-04-2012
290.00
44.90
20.50
0.10
265.00
43.00
334.90
47.40
21800
75.17
566.95
154.04
64.7
14.50
09-04-2012
296.00
40.80
20.60
0.80
270.00
57.00
336.80
30.40
22050
136
74.49
656.29
0.00
65.0
15.50
10-04-2012
300.00
37.30
20.80
1.80
253.00
60.00
337.30
45.10
22660
56
75.53
591.29
21.89
65.3
19.25
11-04-2012
290.00
37.20
20.20
0.20
263.00
51.00
327.20
33.40
21620
72
74.55
547.88
73.47
63.3
13.00
12-04-2012
294.00
39.50
20.50
0.40
104.00
53.00
333.50
197.00
21650
104
73.64
558.05
0.00
64.5
13.00
13-04-2012
298.00
41.90
20.50
0.60
300.00
47.00
339.90
13.40
21530
68
72.25
493.55
69.70
65.8
14.75
14-04-2012
297.00
42.10
20.80
1.40
300.00
47.00
339.10
12.90
22070
74.31
497.45
20.40
65.5
15.25
15-04-2012
295.00
43.50
20.60
1.50
300.00
44.00
338.50
15.10
21590
73.19
452.35
30.96
65.3
13.00
16-04-2012
300.00
44.00
20.80
1.20
300.00
56.00
344.00
8.80
22400
268
74.67
418.01
71.92
66.5
19.75
17-04-2012
296.00
40.00
20.60
2.90
300.00
56.00
336.00
0.60
21550
600
72.80
423.43
0.00
65.0
17.00
18-04-2012
304.00
41.00
21.50
2.90
323.00
58.00
345.00
-14.50
22340
572
73.49
358.43
55.53
66.8
17.00
19-04-2012
303.00
37.60
20.90
4.40
277.00
81.00
340.60
3.50
22010
648
72.64
347.16
64.70
66.0
20.25
20-04-2012
314.00
43.50
21.70
2.90
298.00
62.00
357.50
19.20
21750
492
69.27
345.86
0.00
69.0
18.75
21-04-2012
303.00
38.50
21.00
2.60
295.00
63.00
341.50
4.50
21850
72.11
276.86
118.84
65.8
18.75
22-04-2012
303.00
43.60
21.10
1.40
295.00
57.00
346.60
15.70
22000
72.61
329.90
58.15
66.9
15.00
23-04-2012
304.00
41.10
21.20
2.90
301.00
63.00
345.10
2.30
22210
316
73.06
321.15
121.03
66.9
16.75
24-04-2012
306.00
42.00
21.00
4.30
292.00
71.00
348.00
6.00
22390
680
73.17
375.28
75.40
67.5
13.50
25-04-2012
306.00
23.50
21.00
4.70
232.00
99.00
329.50
19.50
21470
856
70.16
383.18
107.85
63.8
13.00
26-04-2012
316.00
42.50
21.70
2.70
297.00
68.00
358.50
15.20
22800
420
72.15
427.23
52.89
69.3
11.00
27-04-2012
315.00
41.00
21.90
2.30
298.00
64.00
356.00
15.90
22400
668
71.11
410.82
150.34
68.9
17.25
28-04-2012
320.00
40.30
21.90
5.90
297.00
72.00
360.30
13.20
22700
70.94
492.26
0.00
69.7
9.00
29-04-2012
319.00
43.00
22.20
2.50
297.00
64.00
362.00
23.20
22550
70.69
422.56
46.88
70
1.75
30-04-2012
316.00
44.70
22.00
1.40
303.00
64.00
360.70
15.70
22170
396
70.16
399.44
79.11
69.8
8.00
8355.00
1121.30
580.50
55.80
7645.00
1866.00
9476.30
545.80
605030.00
7928.00
6596.00
72.42
1661.38
1834.30
450.00
TOTAL

Monthly monitoring format Thermal Energy
BOILER MONTHLY REPORT
April '11
May ' 11
June ' 11
July ' 11
August ' 11
September' 11
October' 11
November' 11
December' 11
January' 12
February' 12
March' 12
2011-12 AVG
STEAM
SH steam generated
MT
7623.00
7781.00
8563.00
7519.00
7439.00
7432.00
7962.00
8665.00
6573.00
7626.00
8248.90
8031.00
7789
Sat steam generated
MT
839.61
935.40
1025.35
996.10
985.70
1018.30
1101.00
1028.76
854.38
1033.75
1210.00
1059.20
1007
LPDSH water spray
MT
527.00
539.50
563.90
508.00
505.30
516.40
545.50
586.60
456.30
521.60
575.30
559.40
534
LP steam vented
MT
92.60
86.73
50.40
30.70
54.30
58.90
70.90
57.30
35.30
59.40
24.70
21.80
Hot condensate consumption
MT
7177.00
7564.00
8361.00
7539.00
7176.00
7435.00
6687.00
8460.00
6472.00
7557.00
7900.00
7175.00
7459
DM water consumption
MT
1803.00
1482.00
1622.00
1383.00
1351.00
1325.00
1149.00
1738.00
971.00
1622.00
1607.00
1656.00
1476
Enthalpy of SH steam
kCal/kg
776.00
776.00
776.00
776.00
776.00
776.00
776.00
776.00
776.00
776.00
776.00
776.00
776
Enthalpy of sat steam
kCal/kg
667.00
667.00
667.00
667.00
667.00
667.00
667.00
667.00
667.00
667.00
667.00
667.00
667
Enthalpy of exhaust steam
kCal/kg
Enthalpy of feed water
707.00
707.00
707.00
707.00
707.00
707.00
707.00
707.00
707.00
707.00
707.00
707.00
54
707
kCal/kg
110.00
110.00
110.00
110.00
110.00
110.00
110.00
110.00
110.00
110.00
110.00
110.00
110
Total water consumption
MT
8980.00
9046.00
9983.00
8922.00
8527.00
8760.00
7836.00
10198.00
7443.00
9179.00
9507.00
8831.00
8934
Total steam generated from boiler
MT
8462.61
8716.40
9588.35
8515.10
8424.70
8450.30
9063.00
9693.76
7427.38
8659.75
9458.90
9090.20
8796
Penta steam consumption
MT
8556.41
8716.40
8776.35
8446.50
8299.30
8300.30
8766.00
8604.76
8505.00
10111.13
9458.90
9090.20
8803
1568.50
1810.40
1769.50
1533.60
1550.90
1600.50
1673.10
1692.20
1621.20
1632
FUEL
MT
1441.90
1777.80
1538.90
6000 GCV coal consumption
MT
1441.90
850.00
0.00
150.00
752.00
800.00
684.00
1455.10
960.30
501.94
846.10
500.00
5600 GCV coal consumption
Total coal consumption
MT
0.00
718.50
1810.40
1619.50
781.60
750.90
1093.80
83.80
640.20
1171.16
846.10
1121.20
886
AFB GCV of 6000 GCV coal
kCal/kg
5193.00
5193.00
5193.00
5193.00
5193.00
5193.00
5193.00
5193.00
5193.00
5193.00
5193.00
5193.00
5193
AFB GCV of 5600 GCV coal
745
kCal/kg
4167.00
4507.32
4507.32
4507.32
4507.32
4507.32
4507.32
4370.73
4370.73
4370.73
4370.73
4370.73
Avg GCV of coal
kCal/kg
5193.00
4878.90
4507.32
4565.44
4843.54
4861.01
4771.13
5148.22
4864.09
4617.42
4781.87
4624.33
4805
Avg coal cost per month
Rs / MT
5392
4934
4381
4443
4776
4841
5190
5066
5165
5586
5397
4808
4998
4422
Heat input to boiler
kCal
7487786700
7652557317
8160046829
8078550000
7428055024
7538944390
8482115415
7922601617
7784980339
7725400566
8091873398
7496964390
7820822999
Heat output from boiler
kCal
5544580770
5703163800
6274077950
5562481700
5503408900
5516905100
5915949000
6343909320
4853507660
5654714750
6167737400
5938620400
5748254729
74.05
74.53
76.89
68.85
74.09
73.18
69.75
80.07
62.34
73.20
76.22
79.21
73.50
5.87
5.56
5.30
4.81
5.49
5.45
5.10
6.30
4.64
5.18
5.59
5.61
5.39
CALCULATIONS
Boiler efficiency (Direct)

Steam - Fuel ratio
TG power generated per MT steam
kW/MT
72.21
71.97
71.09
72.91
72.79
74.35
75.38
73.86
73.35
73.12
75.55
74.11
73.39
kg/kW-hr
13.85
13.89
14.07
13.72
13.74
13.45
13.27
13.54
13.63
13.68
13.24
13.49
13.63
1.09
1.00
0.53
0.36
0.64
0.70
0.78
0.59
0.48
0.69
0.26
0.24
0.61
Fuel towards power generation
MT
136.79
147.66
170.49
165.04
143.04
144.16
165.09
145.03
149.56
155.69
156.16
151.28
152
Fuel towards process applications
MT
1305.11
1420.84
1639.91
1604.46
1390.56
1406.74
1612.71
1393.87
1450.94
1517.41
1536.04
1469.92
1479
9.09
9.09
9.09
9.09
9.09
9.09
9.09
9.09
9.09
9.09
9.09
9.09
9.09
TG Power Generation cost
Rs / kW
1.34
1.30
1.23
1.34
1.26
1.26
1.43
1.15
1.60
1.56
1.35
1.22
1.33
Steam Generation cost
Rs / MT
908.64
887.86
903.69
930.71
882.62
904.53
1052.56
905.99
971.91
924.35
965.58
857.49
926.41
MT
450.00
450.00
450.00
450.00
450.00
450.00
450.00
450.00
450.00
450.00
450.00
450.00
450.00
Specific steam cons in TG

% steam vented to generated
Heat - Power ratio of power plant
PENTA
Penta production
Specific steam cons by plant
MT / MT PE
18.81
19.37
21.31
18.92
18.72
18.78
20.14
21.54
16.51
19.24
21.02
20.20
19.55
Specific power cons by plant
kW / MT PE
1347.44
1379.57
1485.94
1351.45
1310.53
1317.28
1429.18
1490.01
1153.85
1274.58
1404.50
1328.11
1356
EQUIVALENT FUEL CONSUMPTION

Total coal consumed
Avg GCV of coal
Boiler efficiency (Direct)
GCV of equivalent fuel
Boiler efficiency with equ. Coal
1441.90
1568.50
1810.40
1769.50
1533.60
1550.90
1777.80
1538.90
1600.50
1673.10
1692.20
1621.20
1632
5193
4879
4507
4565
4844
4861
4771
5148
4864
4617
4782
4624
4805
kCal/kg
3500
3500
3500
3500
3500
3500
3500
3500
3500
3500
3500
3500
3500
MT
2139.37
2207.81
2331.44
2308.16
2092.88
2146.36
2420.24
2269.65
2224.28
2207.26
2311.96
2141.99
2240
kg/MTsteam
250.03
253.29
265.65
273.27
252.18
258.59
276.09
263.77
261.53
218.30
244.42
235.64
254
842
Equivalent coal consumption
Specific equ. Coal consumption
MT
kCal/kg
Steam Cost (Coal handling charges not included)

Budjeted steam cost
Rs / MT
842
842
842
842
842
842
842
842
842
842
842
842
Actual steam cost
Rs / MT
909
888
904
931
883
905
1053
906
972
924
966
857
925
-7.91
-5.45
-7.33
-10.54
-4.82
-7.43
-25.01
-7.60
-15.43
-9.78
-14.68
-1.84
-9.82
% Variance wrt budget
COGEN PLANT EFFICIENCY

Efficiency is calculated on daily basis by direct method.
Belt Weighment scale is fixed in the feed belt conveyor & used for
measuring fuel quantity.
Boiler energy audit is carried out once in a year by expert consultants.
90 to 95% of hot condensate is returned to boiler.
All critical parameters of the captive plant are connected on line to
Managers/Executives for effective monitoring through internet.
ELECTRICAL ENERGY
Electrical power tree is prepared to monitor fixed and variable power

consumption.
KWhr consumption is monitored for overall plant and individual

sections and the consumption is compared with production and any
variation is reasoned out.
Equipment running hours are monitored on daily basis to identify

idle running/under loading of the machineries
Utility report is generated on daily basis which captures specific

power, steam and water consumption.
Any deviation of the specific consumption figures from the Budget

is captured in terms of LOSS/GAIN in Rupees on daily basis.
MODEL ENERGY MONITORING FORMAT
MODEL ENERGY MONITORING FORMAT

Daily Power consumption report
Monthly Power consumption report
IMPLEMENTATION OF SUGGESTIONS
Energy week is celebrated in the month of December to emphasize the
importance of energy conservation across the factory.
Energy conservation related ideas received from employees through
suggestion scheme is evaluated,
ideas worth implementing are
rewarded with Energy Efficient Gadgets
Total no of suggestions received in 11-12
- 22
No of suggestions implemented
- 17
On completion of the project, IRR projected and IRR actually realized is

compared.
To improve the awareness on Energy conservation, CFL lamps issued to
all daily contact workmen during the safety week celebrations
March2012.
IMPLEMENTATION OF SUGGESTIONS
Replacement of 150W SV lamps with 45 W LED street light fittings.
Before
After
RENEWABLE ENERGY PROJECTS

Installed Natural draft air ventilators on top of Stores, Workshop and
Boiler, investment made RL 1.55 and Savings RL 1.7/annum due to
stoppage of power driven exhaust fans. Extending the same facility to
Coal storage sheds this year.
5% of entire plant roof is converted into transparent PVC sheets,
thereby achieving saving of 0.4RL/annum in lighting system.
As an alternate to the coal, we also use Rice husk as a co-fuel in the
Boiler.
Contd . . .
RENEWABLE ENERGY PROJECTS

Solar Water heating system to Industrial Dish Washing application in
canteen at a cost of RL 2.2, thereby achieving saving of 1.18
RL/annum.
ENCON efforts for future
Reduction of throttling losses across TG by Modification of Nozzle

plates.
Reducing the head pressure of Boiler De-aerator feed water pumps.
Installation of VFD for Instrument Air compressor.
Power conservation by effluent reduction at source.
Reducing the surface moisture of coal by installing Turbo ventilators
in Coal storage sheds.
Replacement of worm gear with inline helical gear for ETP aerator.
Replacement of pneumatic level instruments with Electronic type.
Installation of Energy Monitoring System.
Optimizing the power consumptions of Vacuum pump in Crude Belt
Filter.
Replacement of conventional Light fittings with LED fittings and Light
pipe.
Installation of solar systems for lighting requirements.
Continuing with phase wise replacement of standard motors with
EFF1 motors.
Encourage employees to qualify as Certified Energy
Manager/Auditor.
Best practices on energy front implemented through

our associates
Persuaded the coal suppliers to shift importing of coal from Chennai to
a nearby port at Karaikal to reduce transportation distance by 200 KM
per trip of truck. Reduction in Diesel consumption by the trucks.
While evaluating the quality of imported coal, special weight age is
given for ash and sulphur content though they do not contribute to
the heat value of the coal. This is based on the environment impact
on account of high ash and high sulphur coal usage.
Increased the Acetaldehyde tanker capacity from 8MT to 16MT to
reduce the number of trips of tanker.Truck movement on this RM
supply has reduced by half.
We have implemented a system for the vehicles used for other plant
works to be completed locally with a predefined schedule thus
avoiding frequent vehicle movement.
IMPLEMENTATION OF CORRECTIVE / PREVENTIVE ACTIONS

FROM ISO 14001 / OHSAS 18001 CERTIFICATION
Date of audit: 27.02.2012
Sl.
No
Standard
Description and
Consequence
Category of
Finding
Corrective
actions
Preventive
Action
ISO
14001:2004
Requirement: ISO 14001:2004

Cl.4.5.3 states that "Actions taken
shall be appropriate to the
magnitude of the problems and the
environmental impacts
encountered. The organization
shall ensure that any necessary
changes are made to
environmental management
system documentation"
Failure: Investigation has not been
done for some environment related
Non-conformance reported during
the recent cyclone.
Evidence: The evidences are
Physically verified for some
location.
Minor/ 4.5.3
EIA impact study

will be completed
for chemical
spillages and
damages in
hazardous
material storage
area and scarp
yard.
Corrective actions
arrived at will be
implemented. This
aspect has been
incorporated in the
procedure manual.
ISO
14001:2004 /
OHSAS
18001
Operational Controls to be
improved in the following area in
the Pentaerythritol Production
Main Control Room (MCR):- Noise
emanating from the MCR AC
Compressor is on the higher side.
Noise level monitoring to be done
here since this Compressor is
running continuously
Observation/
4.4.6
AC compressor
area will be
included in the
Noise survey
monitoring area
and periodic
monitoring of
Noise will be
done.
Effectiveness is
being ensured
during internal
monthly EHS
meeting.
Awards and Recognitions.
We have won "The Environmental

Best practices Award for Most
Innovative Environmental project
by CII in Jan2011
Challenges faced during THANE cyclone

Our plant got devastated during Thane cyclone on 30th Dec 2011
With concentrated team efforts we overcame the challenges and
restored the plant to achieve the targeted production.
Before Cyclone
After restoration
EXISTENCE OF HUMAN RACE IS CENTERED

AROUND ENERGY
ENERGY IS THE BREATH OF INDUSTRY.
IT CAN NEITHER BE CREATED NOR DESTROYED. BUT

CAN BE CONSERVED.
THANK YOU !!!

Asian Paints Limited Penta Division Cuddalore

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EXCELLENCE IN ENERGY

PROCESS BLOCK DIAGRAM

Crude Mother Liquor

Electrical Energy Cost

The Co-Gen system generates

ENERGY CONSERVATION ACTIVITIES 2009 to 2012

Replacing Crude Belt Filter

Replacing Pure Belt Filter

Replacing the low pressure

Reducing 1500 KVA Turbo

Firing of Waste gas

Installation of 2Nos of 18.5

Reducing Cooling Water

Optimization of Batch cycle time in

Increasing the Power throughput

Replacing 150 W, HPSV

Replacing Electric storage

Installation of a Boiler steam

Reducing the plant operation

Reducing the steam

Reducing the water ingress

Reducing Power consumption

Increasing the Power

Reducing the Power

Replacing 150 W, HPSV Street

Other miscellaneous projects

Reducing Power consumption

Increasing the Power

Reducing the Power

Replacing 150 W, HPSV Street

Other miscellaneous projects

INTERNATIONAL NORMS VIS--VIS OUR PERFORMANCE

** Norms specified by the Technology provider M/s.Hercules Inc.,USA.

IMPACT ON SPECIFIC POWER / STEAM CONSUMPTION

TREND- SPECIFIC POWER CONSUMPTION

A whopping reduction of 52% in Power Consumption

TREND- SPECIFIC POWER CONSUMPTION

TREND - SPECIFIC STEAM CONSUMPTION

19.20 19.25 19.00 19.08

22.8 20.8 18.4

19.5 19.8 19.6

A whopping reduction of 41.3 % in Steam Consumption

TREND - SPECIFIC STEAM CONSUMPTION

We have commissioned a Zero liquid Discharge system

PROCESS BLOCK DIAGRAM

Crude Mother Liquor

Reaction batches per day

Penta Production per day

Pure Penta Solution

Recycled Penta Solution

Pure Penta Solution

Recycled Penta Solution

Feed streams pumping time

Tech Dissolver Batches per

Batch Cycle time

Penta Production per day

: 3.13 Lac units

1 Methanol Feed concentration

2 Reactor conversion efficiency

3 Unreacted Methanol fed to

4 Steam to Distillation Column

CAC Wash Header

Spent wash liquor to Evaporator

Spent wash liquor to Evaporator