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The Presentation ON: Satus of The PSF Plant Operation

This document provides a presentation on the status of production at the PSF plant from January 2004 to June 2004. It includes the following key points: 1) The plant achieved a capacity utilization of 99.96% in May 2004, which was the highest level since commissioning. 2) Production and capacity utilization increased each month from January to May, before declining slightly in June. 3) Specific consumption of raw materials and utilities like DMT, MEG, power, and steam decreased each month and approached target levels. 4) Actions were taken to address equipment issues and improve insulation to increase throughput and reduce costs. 5) With price increases and other benefits, a positive contribution was expected for August

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Kaushik Singha
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58 views24 pages

The Presentation ON: Satus of The PSF Plant Operation

This document provides a presentation on the status of production at the PSF plant from January 2004 to June 2004. It includes the following key points: 1) The plant achieved a capacity utilization of 99.96% in May 2004, which was the highest level since commissioning. 2) Production and capacity utilization increased each month from January to May, before declining slightly in June. 3) Specific consumption of raw materials and utilities like DMT, MEG, power, and steam decreased each month and approached target levels. 4) Actions were taken to address equipment issues and improve insulation to increase throughput and reduce costs. 5) With price increases and other benefits, a positive contribution was expected for August

Uploaded by

Kaushik Singha
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
You are on page 1/ 24

THE PRESENTATION

ON
SATUS OF THE PSF PLANT
OPERATION

DATED : Jul2004

CAPACITY UTILIZATION PSF


120
% UTILIZATION

100
80

86.72

60
59.84

40
20

94.5

99.9

93.4

67.84

23.4

0
Dec'03

Jan'04

Feb'04

Mar' 04

Apr' 04

May'04

Jun'04

The Plant has achieved a capacity utilization of 99.96% during the month of
May, which is the highest ever achieved since commissioning.

A. SUMMARY OF PSF PRODUCTION

Jan04

Feb04

Mar 04

Apr04

May04

Jun,04

Production 1903.10
(MT)

1948.96 2669.43

2909.07 3179.40 2874.98

Capacity
utilization
%

63.31

94.51

61.82

86.72

99.96

93.40

SPECIFIC CONSUMPTION OF MAJOR


RAWMATERIALS & UTILITIES - PSF
ITEM

UNIT

ACTUAL ACHIEVED

STAND.

Jan04

Feb04

Mar04

Apr04

May04 Jun04

DMT

MT/MT

1.02

1.052

1.064

1.076

1.053

1.032

1.029

MEG

MT/MT

0.35

0.398

0.398

0.355

0.365

0.359

0.362

MWH/MT

0.800

1.005

0.953

0.82

0.746

0.734

0.818

FUEL

MT/MT

0.121

0.129

0.116

0.078

0.064

0.065

0.051

STEAM

MT/MT

3.00

5.858

5.54

4.82

4.639

4.544

4.798

WASTE

5.08

6.99

5.21

4.52

4.46

POWER

The specific consumption of Raw materials utilities and wastes are showing an
improving trend and approaching the target value.

SPECIFIC CONSUMPTION OF MAJOR RAW


MATERIALS & UTILITIES - DMT
ITEM

UNIT

ACTUAL ACHIEVED

STAND.

Jan04

Feb04

Mar04

Apr04

May04 Jun04

P-Xylene

MT

0.651

0.66

0.64

0.66

0.65

0.63

0.65

Methanol

MT

0.417

0.46

0.42

0.44

0.42

0.42

0.44

Cobalt
Acetate

KG

1.18

1.06

1.32

1.28

1.08

0.12

0.26

Manganese
Acetate

KG

0.113

0.1

0.12

0.13

0.11

0.01

0.03

Acetic acid

KG

0.235

0.18

0.19

0.15

0.09

0.01

0.04

Steam

MT

4.5

5.95

5.80

4.73

3.81

3.58

3.17

The specific consumption of Raw materials utilities and wastes are showing an
improving trend and approaching the target value.

REASONS FOR DEVIALTION IN SPECIFIC


CONSUMPTION OF RAW MATERIALS & UTILITIES
PSF

Startup of plant after prolonged shut-down.


Number of unscheduled shutdown due to failure of
critical equipments.

Failure of Dow vaporizers.


Failure of Chiller compressors.
Failure of spinning puller roll drives.
Interruption in plant air supply.
Total complex power failure.
Local power failures.
DMT flow loss due to Submerging of offsite process lines in
heavy rains.
High level of water content in fuel oil.

High level of waste generation.


Poor thermal insulation.

REASONS FOR DEVIATION IN SPECIFIC


CONSUMPTION OF RAW MATERIALS - DMT
Startup of plant after prolonged shut-down.
Built up of in plant inventory as plant started from empty
conditions.
Fluctuation in throughput due to ullage constraints, short
supply of raw material & equipment breakdowns.
AC (activated carbon) unit leakages and bed displacement
leading to poorer recovery of P-Xylene.
Waste Heat Boiler tube failure.
Poor condition of steam traps and line insulation.
High rate of stream recycle, thereby lowering conversions in
Oxidation reactions.

B. SUMMARY OF SALES & CONTRIBUTION

Jan 04

Feb 04

Mar 04

Apr04

May04

2792

3576

Jun,04

Sales
(MT)

162.614 1062.165 2316.92

Contribn.
(Rs/MT)

(-) 5681

(-) 4799

(-) 2110 (-) 4461 (-) 2969

324

Contribn.

(-) 0.09

(-) 0.51

(-) 0.49

0.12

Rs. Crores

(-) 1.26

(-) 1.06

3560.550

REASONS IDENTIFIED FOR NEGATIVE


CONTRIBUTION

High raw material price vis--vis finished fibre


price
Higher transfer price of DMT.
Higher specific consumption of raw materials &
utilities
DMT, EG high level of waste.
Steam poor insulation, submerging/water ingress in the
insulations.

Low first grade quality production


Unscheduled interruptions leading to production
loss & high level of waste generation.

ACTIONS TAKEN FOR IMPROVING CONTRIBUTION.


DMT PLANT:
Steam trap replacement (246 Nos) based on a survey by Forbes Marshall.
DMT - Waste heat boiler repaired and put in line.
Stabilization of RMCR unit. Maximizing catalyst Cobalt recovery.
Process parameters optimized to reduce HBs recycle in C&C.
Reduction in steam consumption below standard conditions to minimize
conversion costs.
Maximizing recovery of organics from waste water streams, resulting in
60% reduction in BOD load.
PSF PLANT:
Proposed replacement of mineral wool insulation with calcium silicate
block insulation.
Draw machine crimpers have been changed to 6.5 inch for improved
productivity.
Damaged insulation of spinning machine replaced.
Reduction in waste generation.

WASTE % OF PSF

% WASTE

8
6
4

6.99
5.21

5.08

4.5

4.46

May'04

J un'04

2
0

J an'04

Feb'04

Mar' 04

Apr' 04

ACTION FOR SUSTAINING FULL THROUGHPUT


OPERATION/ IMPROVING CONTRIBUTION

Chiller compressor needs replacement.


1st phase 950 TR one no.- by Feb05. Investment 1.5crores.
2nd phase 450TR two nos. by 2005. Investment 2 crores.

Tubes: 85% in Vappouriser - I and 15% in


vapouriser II to be replaced
Above can be taken up after vapouriser III is made ready
(total tube replacement) expected investment 0.36 crores.

Burners & control system up-gradation in all


vaporizer expected investment 1.9 crores.
Spinning puller roll & metering pump drive
replacement. expected investment 1.0 crores.

ACTION FOR SUSTAINING FULL THROUGHPUT


OPERATION/ IMPROVING CONTRIBUTION

Control system up gradation of DM#1, 2 & tow


pack station.
Being planned new. Expected investment 0.5 crores.

DMT & EG auto feed control system based on out


put.
Being planned new. Expected investment 0.5 crores.

Control system up-gradation in the baler area.


Being planned new. Expected investment 0.4 crores.

Additional cutters.
Being planned new. Expected investment 0.7

ACTION FOR SUSTAINING FULL THROUGHPUT


OPERATION/ IMPROVING CONTRIBUTION-DMT

De-bottlenecking of DMT plant


Insulation replacement.

FUTURE TREND
PSF price showing an improving trend.
More benefit to customer on buying BRPL fibre as
compared to other manufacturers due to changed duty
structure on spun yarn.
Reduction of AGST & CST to 1% (effective 1.1%) by
Assam Govt. will bring in additional benefits.
Sales logistics being reframed to improve realization.
Expected positive contribution for the month of August04
is of the order of 1500/MT (1.65 crores).

PRICE TREND
80000

Rs PER MT

70000
60000

63000

65000

65000

65500

63000

63000

64000

46798

47145

65000

50000
40000
30000
20000

41331
30926

41018
30700.89

44882

46144

34090

34875

47211

36878.19 36720.89 37424.77

49331
37425

68500

52313
37425

10000
0

PSF
P- XYLENE
MEG

OTHER BENEFITS
Additional benefits accurse to the company by
way of improved CPP effiency.
Approx. 2.5 crores per annum gain (not taken in contribution
calculation)

Utilization of idle manpower of the company.


Improved work environment.
Large scale indirect employment generation due to
increased activities like bagging, loading,
dispatching etc.

PSF NEW PROJECT STATUS


Limited tender floated to 9 parties on 11th
March04.
Offer received only from Chemtex/Invista on 19th
April04
Offer opened on 4th May04.
Discussion held with the party on 8th July04.
Propritory/non propritory & service scopes were
redefined.
Revised price offer expected by 1st week of
August04.
Project viability will be re-casted after receipt of
revised offer for taking a final view on the project.

FIRST GRADE QUALITY PRODUCTION


100

Target - 95 %

% 1ST GRADE

90
80
70
60
50

84.4

90.0

92.56

89.9

75.6
66

40
30
20
10
0

J an'04

Feb'04

Mar'04

Apr' 04

May'04

J un'04

PER MT OF PSF

CONSUMPTION TREND FOR DMT


1.09
1.08
1.07
1.06
1.05
1.04
1.03
1.02
1.01
1

1.079
1.064
1.053

1.052

J an'04

Feb'04

Mar' 04

Apr' 04

1.032

1.029

May'04

J un'04

PER MT OF PSF

MEG CONSUMPTION TREND


0.41
0.4
0.39
0.38
0.37
0.36
0.35
0.34
0.33

0.398

0.365
0.355

J an'04

Feb'04

Mar' 04

0.359

0.362

0.364

Apr' 04

May'04

J un'04

POWER CONSUMPTION TREND


1.2

1.005

0.953

MWH PER MT

0.82

0.746

0.734

Apr' 04

May'04

0.818

0.8
0.6
0.4
0.2
0
J an'04

Feb'04

Mar' 04

J un'04

STEAM CONSUMPTION TREND


7
PER MT OF PSF

6
5

5.858

5.54

4.82

4.639

4.544

4.334

Apr' 04

May'04

J un'04

3
2
1
0
J an'04

Feb'04

Mar' 04

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