Imagination at work
Case study on Energy Saving Solutions for Fertilizer Plants
February 16, 2016
Introduction
GE Study on Energy Efficiency
Efficiency Improvement… Analysis
GE’s Energy Saving Solutions
GE Digital Solutions
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We are at work as one company to invent the next industrial era.
And create things that build, move, power, and cure our world.
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GE innovates, partners and develops technology solutions that help improve quality of life in India.
GE in South Asia
13,000+ employees
5,300+ engineers
JV with Indian partners like Wipro, SBI, BHEL & Triveni
First GE multi-modal manufacturing site
$1 Billion of global sourcing spend
10 Manufacturing sites
In India, for India, for world.
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» Vast experience of GE NP – Playing a leadership role
» Single source supplier for both drivers and driven equipment
» Vast Product Portfolio
Gas Turbines & Steam Turbines
Centrifugal Compressors & Reciprocating Compressors
Turbo expanders- For power generation or as mech. drives
Pumps & Hydraulic power recovery turbines (HPRT)
Generators, Motors, Control systems
» Historic engagement with all major process Licensors and EPCs
» Customised solutions to meet any application/operational challenges
» Well established India foot print for spares parts and service support
GE Oil & Gas ………………….A PIONEER in the rotating machinery applications
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GE Oil & Gas – Experience in Fertilizer Industry
»More than 100 turbo compressor trains in 34 countries
»80+ years of technology leadership in the urea fertilizer production Market
»First compressor train in 1920 for 400 TPD plant
»Today Compressor train for 3800 TPD plants
»14 projects in Ammonia and Urea Synthesis in last 10 years
Extensive range, experience and expertise
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Study on Energy Efficiency – Customer Engagement
GE undertook a study to outline a roadmap towards energy efficiency and to enable customers to meet their specific energy targets.
Capturing Customer
Requirements
Visited customer site to discuss plant layout,
issues, collect necessary data, etc.
GE’s Internal Study
Evaluated possible energy saving solutions,
carry out calculations based on information
collected.
Solution Proposal by GE
Visit to customer with energy saving solutions proposal with benefits.
Our Approach…
Case Study 1 Urea production capacity of ~5500 MTPD with energy consumption of
~6.2 Gcal/MT of Urea
Case Study 2 Urea production capacity of ~3200 MTPD with energy consumption of
~5.2 Gcal/MT of Urea
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Efficiency Improvement
Reducing energy consumption of
existing process/equipment
Maximizing the throughput of existing unit
Independent GE Solutions
GE Solutions along with Energy Consultant
GE’s experience in products & services in O&G industry can contribute significantly towards reducing energy consumption of the existing process/equipment.
“The solutions identified through our case study are scalable and applicable across other fertilizer plants and designs.”
Efficiency Improvement… Analysis
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Efficiency Improvement… Analysis
~15% reduction in auxiliary load
for a Group I,II plant
~40% reduction in auxiliary load
for a Group III plant
“Optimizing auxiliary load consumption of plant is
relatively easier route towards energy efficiency”
Reduce energy consumption of auxiliary load
Reduce auxiliary load of a plant
Reduce fuel consumption of same
auxiliary load
GE Digital Solutions
Retrofit/upgrading existing equipment
Upgraded design to facilitate
plant/process change
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GE’s Energy Saving Solutions
4. Gas Turbine Performance Enhancement Kit (PEK)
For a typical 25MW GT, power output can be increased by ~4%
Retrofit/upgrading existing equipment
2. VAM (Chiller) in Air Compressor Inlet
Industry best practice…for maintaining consistent inlet air temperature.
~250 KW saving of power by installing at the inlet line of air compressors
1. Compressor train upgrade
Technology advancements in last 2 decades
~ 5-10% reduction in steam requirement of ST
& up to 5% capacity increase
3. Improve existing Hydraulic Turbine for higher power recovery
Capacity enhancement to recover power from bypass stream.
~250 KW of additional power can be recovered from the
bypassed stream
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GE’s Energy Saving Solutions Upgraded design to facilitate either plant/process change
1. Hydraulic Turbine in liquid Ammonia (NH3) stream
Typically liquid NH3 from synthesis loop is let down from ~180 to ~ 20 barg
~300 KW of power recovery from the stream with flow rate of 70-80 TPH
2. Turbo-expander in the Fuel Gas
Typically NG fuel is throttled from ~40 barg (depending on source) to ~5
barg for reformer.
~1.3-1.5 MW power recovery from this high pressure NG supply
3. Waste Heat Recovery from Flue Gas
Organic Rankine Cycle (ORC) system recovers waste heat energy from
Gas Turbines exhaust (or similar waste heat sources)
~500 KW power recovery from flue gas
4. Piping layout improvement
GE has engineering expertise and tools to perform piping pressure loss analysis to
improve performance of the equipment.
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GE’s Energy Saving Solutions Reduce fuel consumption of same auxiliary load
Gas Turbine based Captive Power Plant
Replacing Boiler with Gas Turbine to produce power can reduce the energy
consumption significantly
**Requires specific plant study to assess the benefits
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GE Digital Solutions Convergence of Operations Technology (OT) and Internet Technology (IT)
Response Max…Full maintenance-event management through Advisory Monitoring &
Diagnostics, Digital Warehouse Management and Digital Outage Planning
Reliability Max…Full equipment lifecycle management solution to minimize unplanned
downtime and optimize performance levels
Unified Operations… A holistic Asset Performance Management (APM) software
solution for faster diagnosis, improve asset performance & availability, and maximize profitability.
A host of digital solutions from GE to optimize an equipment, a unit, or a plant and can be extended at an enterprise level.
© 2015 General Electric Company
Advisory Monitoring & Diagnostics
Digital Warehouse Management
Digital Outage Planning
SERVICES
EXPERTISE
Early warning
Trip reduction
Remote tuning
Condition-based maintenance
Inventory digitization
Maintenance Engineer enabled by Software
ERP integration
Part in/out tracking
Security stock monitoring
Need identification
Part netting
Full demand management
Part kitting
CUSTOMER PORTAL
Response Max Capabilities
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• Increased operational visibility
• Improved process and resource efficiencies
• Optimized performance through scaling best practices
• Reduced cost and risk
Equipment OEM
agnostic
Rotating and static
equipment
Visibility at the
equipment, system,
plant, and fleet levels
Everything within the
context of the
Equipment
Unified Operations Capabilities
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