Reducing steam consumption and OPEX at a leading fragrance specialty chemicals manufacturer in South Asia

The plant was experiencing severe steam-related production bottlenecks, with inadequate steam pressure in two blocks disrupting the productivity of distillation columns. Along with this, a higher Specific Steam Consumption (SSC) vis-a-vis plant’s energy consumption norms for each of their products was contributing to the inefficiencies.

Forbes Marshall offered an end-to-end solution comprising audit, design consultancy, product supply, technical supervision and quantification of savings. Our solution eliminated production bottlenecks, improved feed water temperature and significantly reduced the specific steam consumption across their product range.

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PROBLEM

High fluctuations and non availability of desired pressure in some blocks leading to productivity issues.

High specific steam consumption.

OBJECTIVE

To address the steam system (pressure drop) bottlenecks which were impacting production.

To identify avenues to reduce the specific steam consumption and steam opex.

SOLUTION

The Forbes Marshall team conducted a detailed study of the plant, identified the gaps and defined corrective actions.

Solutions were implemented, with appropriate products where required, for –

– Proper desuperheating of steam before supply to the process

– Addressing losses in the steam distribution network

– Steam trapping throughout the plant including for distillation columns and reactors

– Segregation of condensate based on pressure and optimising recovery of condensate and flash steam

– Addressing steam pressure drop and fluctuation issues in the distribution network and pressure optimisation of individual blocks

– Addressing condensate evacuation issues

BENEFITS

Reduction in steam consumption from 731TPD to 675TPD.

Reduced specific energy consumption (Ton/Ton)
Product 1 – 3.3 to 2.3; Product 2 – 8.06 to 7; Product 3 – 9.3 to 6;
Product 4 – 9.4 to 7; Product 5 – 36 to33; Product 6 – 2.9 to 2

14% improvement in condensate recovery factor (from 56% to 70%)

20°C rise in feedwater temperature

No water hammer or direct leaks thereby ensuring safety of the steam network

Improved productivity due to steady pressure at all blocks and equipment including distillation columns and ejectors