Presentation Energy Audit 281105

ENERGY Conservation Consultancy By Ravindra M Datar

Senergy Consultants (P) Ltd www.senergy.co.in [email protected] 91-22-55993086

Why Conserve?     

Product need to be internationally competitive. Cost raises but selling price stagnates. Savings is surest way to increase profits. 10-25% saving can be realized in many industries; half of which with small investment.   The nation gains as  A new captive power plant take 4 years to construct; while benefits of savings can be enjoyed in 6 months.  The power plant costs Rs 50,000/- per kW, while savings costs are not even Rs 10,000/- per kW.

Senergy Synergy between Our expertise on conservation of energy & Your experience & knowledge of process, operations, plant engineering, etc. To Save Energy

Senergy is • An ISO 9001-2000 company. • In this field for more than 14 years. • Team of experts headed by a technocrat

from IIT - Mumbai. • A company with customer Base of 300 industries. • Customer driven company with many repeat orders & orders form group companies. • Approved by MEDA & GEDA. • Contributing Rs 50 crores/year, towards conservation of energy.

Senergy • Provides Personalised services. • Conducts comprehensive & interactive

studies. • Gives practical & realistic recommendations. • Provides services till actual realization of saving. • Can organize subsidies and soft loans. • Take responsibility for turnkey implementation, on specific requests.

Few of our clients • • • • • • • • • • •

Century Enka Ltd Century Rayon Nanavati Hospital Essel World EBG India Pvt Ltd JBF Industries Ltd Emco Ltd PepsiCo India Ltd ICI Ltd Essel Propack Ltd MSEB

• • • • • • • • • • •

Hindustan Lever Ltd Nicolas Piramal India Ltd Wyeth Lederle Ltd Nirlon Ltd GTC Industries Ltd Advani Oerlikon Ltd Frigerio Conserva Allana Ltd Whirlpool of India Ltd Pidilite Industries Ltd Sumaira Group (Tanzania) Ceylon Glass Company Ltd

Senergy: Activities • Energy Conservation Consultancy. • Promotion of Renewable Energy Sources. • Turnkey consultancy for non-standard suggestions. • Consultancy for Process Audit & Yield Improvement.

• Consultancy for Proficient Plant Operations.

Road Map: Energy Conservation Consultancy 1. Team formation 2. Overview of Process & Operations 3. Analysis of Specific Energy Consumption 4. Energy Accounting & Balancing 5. Energy Consumers / Converters 6. Distribution Systems 7. Utilization systems 8. Identification of potential saving areas 9. Implementation 10.Monitoring

TEAM • Participation of all concerned. • Positive suggestions through various schemes. • Immediate & correct evaluation of suggestions. • Positive solutions for roadblocks / problem areas. • Wider acceptance for recommendation. • Quick and effective implementation. • Development of knowledge bank. • Continual improvements. • Savings on sustainable basis.

Overview of Process / Operations • Brief description of activities, with

emphasis of major consumers. • Process / Material flow diagram. • Utilization pattern for major consumers. • Co-relate the critical parameters at the point of generation & utilization – Air pressure at compressor outlet / point of utilization – Suction pressure of refrigeration compressor / process temperature

Specific Energy Consumption Specific energy is the energy consumed per unit output. Analyze variations with respect to – – –

Output Seasonal variations Yield

Start the analysis at Macro-level then Proceed towards Micro-level

Example 34

Specific Energy Consumption

Stage Final

32

Sp Energy (Rs/kg)

Initial

Ideal

30 28 26 24 22 20 1000

1050

1100

1150

1200

1250

Production (kg/day)

1300

1350

1400

Energy Accounting / Balance Prepare break up of consumption for each form of energy by – Measuring energy consumption of individual equipment. – Noting down operating period. – Take data from various sub-meters

Compare total consumption as estimated above with actual consumption to ascertain – “Unaccounted” or “Miscellaneous” portion of the consumption

Analyze consumption pattern (wrt time)

Example

Energy Accounting / Balancing Description Illumination Air conditioning Computers Pumps Electrical Heating Residential & Commercial Miscellaneous Total

% 30% 20% 7.5% 12.5% 2.5% 15% 12.5% 100%

kWh/M 5,40,000 3,60,000 1,35,000 2,25,000 45,000 2,70,000 2,25,000 18,00,000

Energy Accounting Description   Residential & Commercial Hostels Pumping Common Lighting Departments Total

Consumption kWh % 270000 15.0% 420000 23.3% 225000 12.5% 120000 6.7% 765000 42.5% 180000 100.0%

Average Power (kW) Month

Overall

22 to 6

6 to 9 & 12 to 18

9 to 12

18 to 22

Aug-04

2525

2096

2658

2979

2746

Sep-04

2545

2111

2687

2930

2807

Oct-04

2591

2177

2690

2962

2918

Nov-04

2390

2016

2472

2732

2700

Dec-04

2092

1706

2194

2500

2329

Jan-05

2204

1825

2287

2519

2539

Feb-05

2152

1772

2265

2479

2414

Mar-05

2693

2144

2851

3116

2950

Apr-05

2855

2416

3001

3308

3061

May-05

2704

2308

2843

3190

2821

Energy Consumers / Converters Evaluate performance of major consumers to Carry out energy balance for the entire system. Check if the equipment operates at design capacity. Estimate efficiency at design / operating capacity. Compute specific energy consumption. List the major losses and estimate their contribution. Discuss & finalize ways to eliminate / minimize the losses and optimize the efficiency /output. – Evaluate possibility of enhancing useful output. – Check feasibility of using cheaper source of energy do the same work. – – – – – –

Basic Definitions Efficiency: Ratio of Energy utilized for useful work to the total energy supplied to the equipment. Ratio of to energy supplied less sum of all losses to the total energy supplied to the equipment. Capacity utilization: Ratio of the Actual output to the Rated output of the equipment. Specific energy consumption: Ratio of the total energy supplied to the equipment to the Actual output.

Specific Power Consumption – Shaft Power (kWh/TR) Evaporator Temp (0C)

Condenser Temperature (OC) 20

25

30

35

40

45

10

0.27

0.33

0.40

0.47

0.55

0.65

5

0.33

0.40

0.48

0.57

0.67

0.79

0

0.41

0.49

0.57

0.67

0.78

0.89

-5

0.50

0.59

0.69

0.80

0.91

1.04

-10

0.60

0.70

0.82

0.94

1.07

1.21

-15

0.73

0.84

0.97

1.10

1.25

1.42

-20

0.87

1.00

1.14

1.29

1.46

1.67

-25

1.04

1.18

1.33

1.51

1.72

1.96

-30

1.23

1.39

1.57

1.78

2.03

2.31

Refrigeration Effect (TR) Evaporator Temp (0C)

Condenser Temperature (OC) 20

25

30

35

40

45

10

100.0

96.8

93.7

90.5

87.3

83.9

5

83.1

80.4

77.7

74.8

71.9

68.9

0

68.4

66.1

63.6

61.1

58.4

55.7

-5

55.9

53.8

51.6

49.3

46.9

44.4

-10

45.0

43.1

41.1

39.1

36.9

34.9

-15

35.7

34.0

32.2

30.3

28.6

27.1

-20

27.8

26.2

24.6

23.1

21.8

20.7

-25

21.1

19.7

18.4

17.4

16.4

15.5

-30

15.5

14.4

13.5

12.7

12.0

11.4

Air Compressor Pr

Sp Power

Bar 1 2 3 4 7 10 15

kW/M3 0.037 0.057 0.077 0.086 0.108 0.128 0.154

Sp Output M3/kW 27.0 17.6 13.0 11.7 9.3 7.8 6.5

Power kW 100 153.3 207.3 231.6 291.6 345.6 416.9

Distribution Systems • Utilities like steam are generated at centralized place &

distributed through out plant. • Such distribution is always associated with drop in energy level. • Distribution losses are such losses expressed as fraction (or percent) of the initial energy. • Such losses can be in in more than one form like pressure drop, heat gain, leakages, etc. • Minimizing such losses is one of the simplest & surest way of conservation of energy.

Example

Distribution Systems Steam

• Insulation • Leakages • Pressure drop – Routing – Line size

• Trapping

– Location – Size – Type

Utilization Systems • Efficient utilization of utilities / energy is of prime

importance. • Conduct energy balance for each form of energy. • Identify critical parameters for utilities. • Validate criticality of process / plant parameters. • Map process / plant requirement with generation for critical parameters. • Quantify waste streams and potential for energy recovery through the same. • Look for more economical source of energy.

Energy Recovery from Effluent Chilled Water

Waste Ice 8.5 TPD

Ch Water 110C

Fresh Water 300C 221m3/day

Process Plate Type Effluent Heat Exchanger 120C

250C E T P

221m3/day

Chilled Water System

1250 TR / 221 M3/day 130C

Identification of

Energy Saving Areas • Analyze the deviations from norms /

normal values. • Identify reasons. • Work out corrective action. • Discuss with TEAM to formulate Action Plan • Make simple but complete fact sheet for each area. • Categorize areas based on ease of implementation, investment, etc.

Implementation • Pick up low hanging fruits – it goes in a great way

to boost up team moral and management support. • Supervise actual implementation • Provide assistance during commissioning & trouble-shooting.

Monitoring • Ensure that the Team is on the right path • • • •

and at correct pace. Measure the actual savings and ensure realization on sustainable basis. Devise monitoring system for key energy consumers & prepare log / data sheets. Install mechanism for suggestion scheme with effective implementation. Monitor specific energy consumption at macro as well as micro level.

In Nutshell 1. Team formation 2. Overview of Process & Operations 3. Analysis of Specific Energy Consumption 4. Energy Accounting & Balancing 5. Energy Consumers / Converters 6. Distribution Systems 7. Utilization systems 8. Identification of potential saving areas 9. Implementation 10.Monitoring

Thank You!