Operational Excellence

Netback Improvement

To improve the netback of MCPI for its survival and growth, under the umbrella of MCPI 4.0, remarkable efforts were made to –

• Improve PTA prices and reduce discounts
• Introduce coastal shipments
• Setting up Stock Point at Hazira for better inventory management and optimising delivery time
• Introduce multiple payment options
• Identify reliable customers

This resulted in Revenue Optimisation, Freight Merit, Price Improvement, Discount Reduction and Strategic Market Positioning, bringing in a total improvement of more than $15/T.

Implementation of Ultrasound Analysis

The adoption of ultrasound analysis has significantly benefited operations. It is used for monitoring electrical systems and low-speed rotating equipment. This approach has resulted in increased uptime, efficiency gains, and production impact. Additionally, it has helped reduce maintenance costs.

Unit Consumption Reduction (Process)

LSHS consumption was reduced through PTA operation optimisation. This resulted in annual savings of INR 1.6 Cr. Methanol consumption was reduced through hydrogen PSA section regeneration flow optimisation that led to annual savings of INR 1.5 Cr.

Water Recycling Plant for Reuse of DMF & ACF Backwash Water

After analysing reject water sources, including Cooling Tower Blowdown, ETP Outlet, Mixed Bed Effluent, and DMF ACF Effluent, they identified a potential for effective recycling. Reject water from the DMF ACF Effluent area was selected for this process. It undergoes a two-stage filtration system in the Water Recycle Plant. After filtration, the water is redirected to the Cooling Tower for reuse. The installation of this plant has resulted in a financial benefit of ₹29.7 lakhs. This initiative contributes to both sustainability and cost savings.

2nd Phase Revamping of the DP Distillation Column

Acetic acid is one of the primary raw materials for Paraxylene in the PTA process. It is vital to the business, and any loss incurred is not profitable. After extensive analysis, the TDD and Project team decided to change the distillation column internals from trays to structured packing. This method was chosen because it involved lower CAPEX and provided early payback. The re-engineering of the process ensures a yearly benefit of ₹1.2 Cr.