INDORAMA VENTURES POLYMERS RAYONG

JUNE-JULY 2016

ENERGY SAVING PROJECT

REPLACEMENT OF MEG TRANSFER PUMP
Prepared by: Vaibhaw Ladha

For my rising senior summer holiday I interned at a chemical factory in Rayong, Thailand. For the first two weeks of
my internship I received an orientation and I studied how the process works and how the different engineering
departments work together. Throughout this process, I was looking for potential improvements I could make in the
factory, therefore I choose to work on this MEG pump because it was feasible with my time frame. This document
outlines the project from investigating the problem to developing specifications and then the financial analysis and
project outcome.

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BACKGROUND

Mono Ethylene Glycol (MEG) is one of the key raw materials in the production of PET resin.
More than 335 kilograms are used for every ton of PET produced.
MEG is provided by PTT chemicals and
it is delivered to the factory and stored
in a silo 92.26m away from the
production plant. As a liquid it is then
pumped to the production factory. The
MEG has two purposes in the factory:
- Raw material for the main
polymerization processes. (This is a
continuous process )
- Batch preparation (mixed with
catalyst and additives whenever
required). This is a controlled
process, and the second pipeline is

controlled by a valve.

There are two pumps which are used

to transport the MEG. One of them will
be on standby whilst the other is
operated.

Problem
The pump which is used to transfer the MEG is over 15 years old. It is in a poor condition and has a high power
consumption due to low efficiency. Furthermore, since the factory is looking to expand, a new pump is required to
handle more volume of MEG flow.

Solution
In order to solve this problem we decided to install a new pump. We would still use one of the old pumps as
backup, but we wanted to find a pump which would satisfy the operating specifications and would be energy
efficient. The solution would also need to have a payback period of less than 3 years.

PROJECT SPECIFICATIONS

In order for the new pump to serve a similar purpose in a more efficient manner, we contacted many
different suppliers to see what kind of products were on offer. After sorting through the different
suppliers we choose KSB Pumps. Bellow are the details of the product.

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Operation Data

Requested Specification

Product Specification

Flow Rate

14.70m

15.12m

Developed Head

80.00m

84.63m

Eciency

Maximum Possible

66.4%

Additional KSB Pump Operation Data

Mass Flow Rate

4.65kg/s

Shuto Head

105.12m

Pump Rotation

2951rpm

Discharge Pressure

9.19 bar

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After all of this data was approved to our specifications and the tests were done on site, the quotation for the
equipment and spare parts was 115,400 baht.

Current Energy Costs with Old Pump

Old Pumps

Hours per Year (hours)

Total

Continuous Process

8.2kW

8030

65846 kWh/year

Continuous+ Batch
Process

9.5kW

730

6935 kWh/year

From the provincial electrical authority, the power cost is 3.25 baht per kilowatt hour. The total usage
electricity usage for both processes is 72781kWh/year, therefore for 1 year the cost is 236,538 baht.

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PERFORMANCE CURVE FOR NEW PUMP

This diagram represents the data for
the high pressure inline pump, quoted
from the manufacturer: KSB. The best
efficiency point (B.E.P) from calculus,
has been indicated on each graph.

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Summary of Results:
Fluid Density: 1107kg/m3
Flow Rate: 15.12m3/h
Power Observed: 5.81kW
Net Positive Suction Head: 1.73m
Eective Impeller diameter: 110.00mm
Eciency: 66.4%

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Diagram of the MEG Silos

DESIGN AND BUILDING OF MOVITECV PUMPS

Design of
Interior

Design of
Exterior and
Implementation
Module

Installment of Pump and Repiping.

Old Pump (now used for

standby)
New Pump with Inverter

CONCLUSION
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Current Energy Costs with New Pump (real value)

New Pump

Old Pump

Hours per Year

(hours)

Total (new pump)

Continuous
Process

3.1kW

8.2kW

8030

24893 kWh/year

Continuous+
Batch Process

4.5kW

9.5kW

730

3285 kWh/year

Total energy required with the old pump (1 year): 72781kW

Total energy required with new pump (1 year): 28178kW
Energy Saved with new pump: 44603kW

Price of 1kW from Province: 3.25 Baht/kW

Total amount saved in 1 year: 144,959 baht

Total cost of project (equipment+ spare parts+ installment):

219,000 baht

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Total saving in 10 years: $41,411
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The payback period is 1.51 years, which
successfully meets the projects goal. The new
vertical pump also has a large spare capacity in
order to uphold future factory expansions.