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ENCON IN THERMAL SYSTEMOrchid chemicals & Pharmaceuticals ltd.

R&D Centre

Bulk API Alathur facility

Bulk API Aurangabad facility

OHC (Formulations) Alathur facility

OHC (Formulations) IKKT Facility

Corporate Office

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ØØ Largest manufacturer of Cephalosporin products in India Largest manufacturer of Cephalosporin products in India

ØØ One among the top five in the world, holding a market share of 4One among the top five in the world, holding a market share of 40 % 0 %

ØØ Alathur facility Turnover Alathur facility Turnover -- Rs.598 Rs.598 CrsCrs..

ØØ Total Work force employed 1200 Total Work force employed 1200

ØØ 100% EOU with ISO 9000, ISO 14000, US100% EOU with ISO 9000, ISO 14000, US--FDA, TGA EDQM, MHRA certificationsFDA, TGA EDQM, MHRA certifications

ØØ Awards Received in 2009Awards Received in 2009--10 10 a.a. British safety council International Safety AwardBritish safety council International Safety Award--20092009b.b. GreentechGreentech Safety Award Safety Award --20092009c.c. G3 Award G3 Award --20092009

COMPANY PROFILE IN BRIEFCOMPANY PROFILE IN BRIEF

QA & QC building Sterile blockSterile clean room

Thermal System (Steam)

Generation Distribution Utilization

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Condensate recovery

• Steam Generation in : 646 Ton / day

• Condensate water recovered : 574 KL / day

• Un recovered condensate water : 25 KL / day

• Condensate recovery : 93 % (as against std:90%

courtesy Forbes)

• Planning to improve by 2% by converting existing direct purged steam heating system into indirect.

Daily Monitoring and Reporting System

Steam condensate recovery3

Water consumption report4

Picture

Steam consumption Report2

Steam Index 1

Monitoring & reportSl.no

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Steam Generation System

ØFurnace Oil Fired Boiler

ØCoal Fired Boiler

ØWaste Heat Recovery Boiler

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FO Fired Conventional Boiler

FEED WATER IN

FLUE GAS

230 °C

90 °C

90 °C 120 °C

FEED WATER IN

FEED WATER IN TO

ECONOMIZER

140 °C

ELECTRONIC AIR FUEL

RATIO CONTROLLER

FEED WATER IN

TO BOILER

FO Fired Energy efficient Boiler

O2 TRIM

Replacement of Conventional FO Fired Boiler with Energy Efficient F.O Fired Boiler

Steam Fuel Ratio : 13.5 Steam Fuel Ratio : 15.5 (As against 14.5 - 15 Ref.Forbes)

150 °C

FO Fired Energy efficient Boiler

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Ø Flue gas temperature reduced from 230°C to 150 °C by providing economizer and feed water pre heater

Ø Electronic operated Ratiotronic System for Atomization (O2 level < 4.0 %)

Ø Online soot blockers to remove carbon deposited on the boiler

Ø Water Pre-heater to avoid corrosion in Economizer

Ø Adequate Heat transfer area in Economizer

Ø Monitoring methodology a) Mass flow meter for Furnace oilb) Vortex flow meter for Steamc) Online trends to monitor Steam, F.O consumption, O2 , CO2 percentage in flue gas

Ø Adequate Heat transfer area in Economizer

Ø Savings - 96.3 Lacs/ annum.

Furnace Oil Fired Energy Efficient Boiler Feature

Ø Adequate heat transfer area provided in air pre heater and economiser to recover maximum heat from Flue gas

Ø Flue gas temperature reduced to 125 °C against conventional system temp.of 140°C.

Ø Auto combustion system and three element controller provided to improve the combustion efficiency

Ø Blowdown water reused for ash Quenching

Ø Ash recirculation system provided to reduce the Unburnt carbon loss

Ø All ID,FD,PA Fans,Pocket feeders,Feed water Pumps are installed with Variable Frequency Drive Motors

Coal Fired Energy Efficient Boiler Feature

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Ø Monitoring methodology Ø Mass flow meter for SteamØ Coal consumption based on Pocket feeder speedØ Online trends to monitor All compartments

temperature and Pressure at difference zones Ø On line analyzer to monitorO2 , CO,SPM,SOX, NOX

percentage in flue gasØ On line conductivity meter to ensure water quality

Ø Steam fuel Ratio is maintaining around 7.25 for a coal of CV of 5500 Kcal/Kg

Coal Fired Energy Efficient Boiler Feature

Coal Fired Energy Efficient Boiler

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CPP – 3.8 MW

STEAM OUTLET 1.8 T/Hr 10 Bar

STEAM PRESSURE

400 °C

230 °C

Existing system :

Waste Heat Recovery Boiler Increasing Tonnage

Features:Ø Boiler Heat transfer area increased to 30%Ø Economiser provided to preheat feed water Ø On line soot blower provided to remove

carbon deposit

Steam Generation : 1.8 TPH @ 10 Bar

Savings : 42 LPA @ 8300 hrs OperationSavings : 7.5 LPA @ 1460 hrs Operation

CPP – 3.8 MW

STEAM OUTLET

2.5 T/Hr 10 BarSTEAM PRESSURE

400 °C

170 °C

Modified system :

Steam Generation : 2.5 TPH @ 10 Bar

ECONOMIZER

35000 m3/hr 35000 m3/hr

Distribution

Ø Steam trap condition monitoring – Every 15 days once

Ø Forbes marshall study reveal that steam loss through traps< 1% (4% for other Pharma plants)

Ø Insulation study being carried out every year.

Ø Flow meters are provided for major steam consumers and the online monitoring system provided.

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HP GENERATION :506 TPD

206

303525

175

35

EVAPORATOR PEE CONCENTRATOR

CRYSTALIZER RECOVERY PRODUCTION

LPGENERATION :225 TPD

75

130

20

RECOVERY PRODUCTION AHUS

Monitoring & Improvement

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Utilization

Ø Specific steam consumption reduction in effluent evaporation system

Ø Optimization of distillation column operation using Aspen Software (Simulation Technology)

Ø Optimum utilization of Energy in Water for injection system (WFI) and Air Handling Units (AHU)

Reduction of Specific Steam Consumption in Effluent Evaporation System

Result: 0.116 Tons/KL reduction in Specific steam consumption & Annualised savings ` 59.16 Lacs / annum

Steam 190.8 Ton/day

@ 8Bar

Steam 219.2 Ton/day

@ 8Bar

Feed 200KL/day @ 2% salt

Feed 200KL/day @ 2% salt

Steam 34.37 Ton / day

11.4 KL/day @ 35% salt35 KL/day @

10% salt35 Tons/ day

160Ton/day @ 2.5 Bar

5KL/day @ 80% salt

Secondary boiler

Reactor

Salt separator

Salt separator

ReactorImpure

condensate to ETP

Secondary boiler

Impure condensate

to ETPSteam condensate

to Boiler

Steam condensate

to Boiler

Steam 11.21 Ton / day

6.4 Tons/ day

5KL/day @ 80% salt

Pure steam to Production & recoveries

Pure steam to Production & recoveries

188 Ton/day @ 2.5 Bar

DM water

DM water

Steam cond. to Boiler

Steam cond. to Boiler

CT water In

CT water Out

CT water In

CT water Out

FeedFeed

HE-101 HE-101

E-101 E-101Impure cond.

to CT /ETPImpure cond. to CT /ETP

Specific Steam consumption : 0.326 Tons/KL of feed Specific Steam consumption : 0.210 Tons/KL of feed

Earlier Process: Modified Process:

Fast Loop Pump

Problems Faced :-Frequent chocking of tubes in HE-101 Dish endLong period for cleaning – 6 Days

Action taken :-Fast loop pump introduced to reduce the tubes chocking High pressure hydro jet introduced for cleaning – 01 day for cleaning

Specific steam consumption saving : 0.116 Tons / KL ; Net Saving achieved : ̀ 59.16 Lacs / annum

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Optimization of distillation column operation using Aspen Software (Simulation Technology)

Features of Aspen Software :

Ø The column operations can be optimized based on energy, impurities, etc. and various constraints like condenser & reboiler duty.

Ø Detailed heat and mass balance Can be calculated for all the unit operations like heater, cooler, condenser and reboiler load for distillation column.

Ø For reducing energy various scenarios can be simulated using sensitivity analysis e.g. change of column pressure, reflux ratio, feed tray location, etc.

Ø Using batch reactor model, we can calculate the optimum reactiontime & temperature in a batch reactor

Ø Existing Practice :Reflux ratio was maintained 8 to separate Ethyl Acetate (EA) & Tetra Hydro Furan(THF) from EA+THF mixture

Ø Modified Practice :Reflux ratio was reduced to 5 from 8 to separate EA & THF from EA+THF mixture without affecting the quality

Ø Investment : ` 2 Lacs

Ø Savings : ` 17 Lacs/Annum (In terms of steam reduction)

Optimization of distillation column operation using Aspen Software (Simulation Technology)

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FLAME ARRESTOR

Solvent feed

Secondary Condenser

(10 m2)CT Water Outlet

CT Water Inlet

-10°C

Primary Condenser

(81 m2)

FT

FTRD-1104

LS

Re-boiler

Reflux

collectionC 1104

Earlier Process:FLAME ARRESTOR

Solvent feed

Secondary Condenser

(10 m2)CT Water Outlet

CT Water Inlet

-10°C

Primary Condenser

(81m2)

FTLS

Re-boiler

Reflux

C 1104

Modified Process:

Optimization of distillation column operation using Aspen Software (Simulation Technology)

RD-1104

Reflux ratio : 8.0 Reflux ratio : 4.14

FT

collection

Investment : ` 2 Lacs & Savings : ` 17 Lacs/Annum (In terms of steam reduction)

1000 Kg 1000 Kg

4800 Kg3625 Kg

600 Kg

875 Kg

5400 Kg 4500 Kg

Net Steam reduction 2.5 Tons/Batch & 1700 Tons/ annum

Optimum utilization of Energy in Water for injection system (WFI) and Air Handling Units (AHU)

10 µ +60°C OUT

CONDITIONED AREA

+5°c Out

0°c Out

+10°c Out

+60°c In

+10°C

OUT

PURIFIED WATER

RECEIVER

+80°C IN

AHU SYSTEMWATER FOR

INJECTION SYSTEM

10 µ+60°C OUT

CONDITIONED AREA

+5°c Out

0°c Out

+10°c Out

+60°c In

+10°C OUT

PURIFIED WATER

RECEIVER

+80°C IN

AHU SYSTEM WATER FOR INJECTION SYSTEM

Steam was used to heat the dehumidified air in AHU and 0°C brine is used to cool the pure steam generated in WFI system

Water is being used to cool the pure steam generator and hot water which is coming out from the WFI is circulated to AHU heating coil

Investment : ` 1 Lacs

Savings Achieved : ` 44.7 Lacs/Annum

Existing system : Modified system :

+35°C IN+35°C IN

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s

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