TCE Resources HCBU Brochure

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Resources

Hydrocarbons & Chemicals


Key Sectors
Hydrocarbons Oil & Gas, refineries, petrochemicals, LNG, terminals and tankages

Speciality
Chemical & Chemicals, speciality chemicals, fertilisers
Fertilisers

FMCG
& Industrial FMCG & Pharmaceuticals, paints, cement, pulp & paper, tyres, glass, fibre optics
Projects

Annuity-based Exclusive services through Dedicated Engineering Centres for international clients
businesses 3D-4D digital solutions, IIoT, remote monitoring and value engineering solutions
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Resources - Hydrocarbons & Chemicals

Quick Facts
Asia’s largest
Africa’s largest Ethiopia’s first paint manufacturing
fertiliser plant PVC Plant facility – 150,000 &
300,000 klpa

Established the first


First Bank Note Rolling Dedicated Engineering Centre
Paper Mill in India to serve as an alliance partner
for Reserve Bank of India to a large petrochemical
major in Saudi Arabia
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Resources - Hydrocarbons & Chemicals


Services
Dedicated Engineering Centres

Tata Consulting Engineers’ Hydrobarbons &


Chemicals Business Unit (HCBU) provides services
related to both client’s Capex and Opex spends.
The HCBU provides unique services through DEC Model: Benefits
Dedicated Engineering Centres (DEC). † Workforce flexibility and resource optimisation
† Agility for ramp ups and ramp downs
The DEC service model works as an extended † Value additions through continuous learning
engineering arm of the partner, in harmony and improvements of core team
with the partner’s ecosystem with aligned † Dedicated delivery centre, professionals &
work processes. systems tied to client ecosystems
† IPR protection through secure servers and
DEC delivery method is managed through access control
milestone delivery and project progress. † State-of-the-art engineering suites to facilitate
Constructibility decisions are enabled in decision making right at the planning stage
simulated 3D-5D platform. † A combination of home team, satellite team
and affiliate partner teams to ensure a closed
loop environment
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Resources - Hydrocarbons & Chemicals

Key Achievements
Project details Value additions

Design alternatives resulting into CAPEX saving of


Upgrade to new
4.8 million USD and 26% footprint reduction;
generation catalyst
Reduced idling time from expected 17 days to 2 days

Retrofitting of control Significant reduction in downtime/shutdown by using


room building external reinforcement

Rectification of misalignment of turbine and compressor


Compressor turbine piping
piping leading to avoidance of complete replacement of the
stress analysis
equipment in compliance with international standards
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Resources - Hydrocarbons & Chemicals


Detailed engineering for LPG import terminal
Ongoing
at Mundra, Gujarat

Design engineering services for fibreglass plant Ongoing

EPCM services for relocation & expansion of


Ongoing
PVC Plant from Malaysia to India

EPCM services for paint project at Punjab Ongoing

EPCM services for chloromethane plant at Dahej Ongoing

Project consultancy services for manufacturing


Bank Note Paper Mill (BNPM)
of currency and bank note paper

EPCM services for decorative paint project Asian Paints Ltd.

Off road tyre manufacturing plant at Bhuj Balkrishna Industries Ltd

EPCM services for off-site and utilities for


Bharat Petroleum Corp
NHT/CCR unit

EPCM services for manufacturing of Nylon-6 Gujarat State Fertilizer

PMC services for PVC and caustic soda


Dejenna Chemical Engineering PLC
manufacturing plant
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Resources - Hydrocarbons & Chemicals

Case Study
Innovative Approach for Process Selection and Tank Design
to Maximise Storage Capacity with Limited Plot Area

Innovative Process Design minimising CapEx and providing integration of


A regional leader in chemical manufacturing the new facility with client’s existing terminal.
and trading was setting up a new hydrocarbon
processing and storage terminal in Middle Further to this, TCE proposed setting up a pilot
East. The client was facing significantly plant to validate the process. Data from the
reduced economic viability due to the need pilot was used to fine tune the design of the
of processing multiple feedstocks in separate commercial facility and scaled up by 30X and
facilities. TCE was engaged as a consultant successfully executed.
to assess and suggest a cost effective way of
dealing with such multiple feedstocks without Highlights:
multifold increase in CapEX which would 1. First such installation for Client.
render the project unviable. 2. Entire basic engineering right from feasibility to
process selection done in-house at TCE-HCBU.
Solution: After a thorough assessment and
evaluation of all the available processes, TCE 3. 14 different separation processes evaluated to
came up with opportunities where a variety of select the right set of 4 process combinations
process mixes or solutions can be distilled to to ensure minimal TotEx, commercial
commercial grade valuable chemicals. advantage and ease of operations.
4. Designed the operation of the columns on a
TCE conceptualised, optimised, simulated campaign basis to ensure smooth switch over
and designed a set of distillation columns from one process to another, with minimal
to operate 4 sets of distinct and varied contamination and interruption to terminal.
purification/separation processes using the
5. Highly optimised process block layout to
same set of distillation columns, there-by
minimise foot print.
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Resources - Hydrocarbons & Chemicals


Optimised Tank Design for
Maximum Storage
The plot area was very small (220 X 130 = 30000
sq. m) and the requirement was to maximise the
storage capacity of the terminal by installing heat reflection capabilities which reduces the
30 tanks of various diameters along with other evaporation of the product stored and hence
facilities. The conventional internal floating roof lowers emission losses. The storage tank heights
would result in a loss of around 1 to 1.5 m height normally in the region were 25 m max. All the
of tank and hence reduced storage capacity. 30 tanks were designed with height of 27 m
instead of usual 25 m height. With this the
Solution: By suggesting Aluminium internal volume is further enhanced.
floating roofs the height of the roof would be
reduced to 350 mm from 500 mm. Through this Following are the benefits due to the value
value addition, the net increase in the storage addition proposed:
volume is around 6000 m3, which is equivalent 1. Ground improvement cost savings
to one tank of 17 m dia X 27 m ht. 2. Foundation cost savings
3. Tank material and labour cost
Intangible benefits like periodic painting can
4. Aluminium floating roof and dome roof cost
be avoided for the floating and dome roofs
and painting cost
can be avoided. Aluminium has excellent
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Key Differentiators
Resources - Hydrocarbons & Chemicals
† Value Chain Integration; Power-Process-Material Handling-Utilities Remote Monitoring

† Schedule Optimisation: 3D/4D Simulation

† Value Engineering: Cost Optimisation, Design Innovations

† Concept to Commissioning: All services provided in house

† Licensor Technology: Neutral

† Proven Expertise, Deep Knowledge – Wide spectrum of projects

† Tata Ethics & Value System confidentiality, and IP protection

† Best in class engineers: Multi-disciplinary talent from top Institutes

Contact
Email: tceconnect@tce.co.in | Website: www.tce.co.in

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