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Billions in Energy Savings through Creativity and Innovation at Fajr Energy

Billions in Energy Savings through Creativity and Innovation at Fajr Energy
(Tuesday, August 15, 2023) 22:18

TEHRAN (NIPNA) -- The water unit of Region One in Fajr Energy Persian Gulf Company has achieved significant energy savings by creatively and innovatively reusing water and utilizing used resin filters, resulting in a 390 billion rial reduction in costs and a decrease in the use of chemicals.

According to Persian Gulf Petrochemical Industries Company (PGPIC), water is recognized as one of the most fundamental needs of the petrochemical industry. Over time and with industrial expansion, as well as climate changes, the demand for water has increased, contributing to water crises worldwide.

Fajr Energy Persian Gulf Company, as the sole concentrated provider of vital services in the Petrochemical Special Economic Zone, supplies the required industrial water for the industries situated in this economic zone.

Through several processes, the company prepares raw water received from the Karun River for numerous applications. In recent years, with industrial growth and increased regional demand, water needs have risen. Simultaneously, climate changes and drought phenomena have led to a decrease in water resources. Consequently, this company has been continuously reducing water consumption by enhancing processes and increasing production equipment efficiency through knowledge-based and creative projects. Most of these projects have been initiated and executed by the employees of this company within the Creativity and Innovation System (the Suggestions System).

One of these projects involves the reuse of high-life resin membranes (over eight years old) in the reverse osmosis process, resulting in a reduction in water waste and a savings of 390 billion rials in the Region One water purification unit. In this project, reverse osmosis-produced water from RO blocks is introduced to blocks containing used membranes to reduce electrical conductivity (conductance or ion quantity). In this process, the water's conductance is reduced from 80 to 5 microsiemens per centimeter. This water, alongside RO-produced water from other RO blocks (membranes with appropriate efficiency), enters the RO water storage tank, leading to a reduction in the electrical conductance of the final water mixture from 80 to 55 microsiemens per centimeter.

Another project involves directly transferring the RO water from used blocks, with a conductance of 5 microsiemens per centimeter, as feed for the demineralized water (DM water) production unit. Instead of introducing RO-produced water from regular blocks to the DM water production filters, this water is introduced to resin filters for DM water production. This leads to an increase in resin lifespan and a reduction in the frequency of regenerating the DM water production filters, resulting in a considerable reduction in consumable chemicals (sulfuric acid and caustic soda) and water waste, in addition to environmental support.

The execution of this project in the water production unit of Region One has led to a 92% reduction in the regeneration frequency of resin filters and a 52% reduction in sulfuric acid consumption, and a 77% reduction in caustic soda consumption over the past six months. This, alongside environmental conservation, has resulted in a 390 billion rial saving.

This project has also been implemented in the water unit of Region Two, where it is anticipated to save 1,000 billion rials within a year. Over the past years, Fajr Energy Persian Gulf Company has executed numerous projects aimed at water consumption reduction and increased equipment efficiency, with most of these projects initiated and implemented by the employees of the company within the Creativity and Innovation System.

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