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Case Study:

A leading fragrance specialty chemicals manufacturer in South Asia


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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