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ENERGY Conservation ENERGY Conservation ConsultancyConsultancy
ByBy
Ravindra M DatarRavindra M Datar
Senergy Consultants (P) LtdSenergy Consultants (P) Ltd
[email protected]@vsnl.com
91-22-5599308691-22-55993086
Why Conserve? Why Conserve?
Product need to be internationally competitive. Product need to be internationally competitive. Cost raises but selling price stagnates. Cost raises but selling price stagnates. Savings is surest way to increase profits. Savings is surest way to increase profits. 10-25% saving can be realized in many 10-25% saving can be realized in many
industries; half of which with small investment. industries; half of which with small investment.
The nation gains as The nation gains as A new captive power plant take 4 years to A new captive power plant take 4 years to
construct; while benefits of savings can be enjoyed construct; while benefits of savings can be enjoyed in 6 months. in 6 months.
The power plant costs Rs 50,000/- per kW, while The power plant costs Rs 50,000/- per kW, while savings costs are not even Rs 10,000/- per kW.savings costs are not even Rs 10,000/- per kW.
Senergy Senergy
Synergy Synergy
between between
Our expertise on conservation of energy Our expertise on conservation of energy
&&
Your experience & knowledge ofYour experience & knowledge of
process, operations, plant engineering, etc. process, operations, plant engineering, etc.
To To
Save EnergySave Energy
Senergy is Senergy is
• An ISO 9001-2000 company. An ISO 9001-2000 company. • In this field for more than 14 years.In this field for more than 14 years.• Team of experts headed by a technocrat Team of experts headed by a technocrat
from IIT - Mumbai. from IIT - Mumbai. • A company with customer Base of 300 A company with customer Base of 300
industries.industries.• Customer driven company with many Customer driven company with many
repeat orders & orders form group repeat orders & orders form group companies.companies.
• Approved by MEDA & GEDA.Approved by MEDA & GEDA.• Contributing Rs 50 crores/year, towards Contributing Rs 50 crores/year, towards
conservation of energy.conservation of energy.
Senergy Senergy
• Provides Personalised services. Provides Personalised services. • Conducts comprehensive & interactive Conducts comprehensive & interactive
studies.studies.• Gives practical & realistic Gives practical & realistic
recommendations.recommendations.• Provides services till actual realization of Provides services till actual realization of
saving. saving. • Can organize subsidies and soft loans.Can organize subsidies and soft loans.• Take responsibility for turnkey Take responsibility for turnkey
implementation, on specific requests.implementation, on specific requests.
Few of our clientsFew of our clients
• Century Enka Ltd Century Enka Ltd
• Century RayonCentury Rayon
• Nanavati Hospital Nanavati Hospital
• Essel World Essel World
• EBG India Pvt LtdEBG India Pvt Ltd
• JBF Industries LtdJBF Industries Ltd
• EEmco Ltdmco Ltd
• PPepsiCo India LtdepsiCo India Ltd
• ICI LtdICI Ltd
• Essel Propack Ltd Essel Propack Ltd
• M S E B M S E B
• Hindustan Lever Ltd Hindustan Lever Ltd
• Nicolas Piramal India LtdNicolas Piramal India Ltd
• Wyeth Lederle Ltd Wyeth Lederle Ltd
• Nirlon Ltd Nirlon Ltd
• GTC Industries LtdGTC Industries Ltd
• Advani Oerlikon LtdAdvani Oerlikon Ltd
• Frigerio Conserva Allana Ltd Frigerio Conserva Allana Ltd
• WhirlWhirlpool of India Ltdpool of India Ltd
• PPidilite Industries Ltdidilite Industries Ltd
• Sumaira Group (Tanzania)Sumaira Group (Tanzania)
• Ceylon Glass Company Ltd Ceylon Glass Company Ltd
Senergy: Activities Senergy: Activities
• Energy Conservation Consultancy. Energy Conservation Consultancy.
• Promotion of Renewable Energy Sources.Promotion of Renewable Energy Sources.
• Turnkey consultancy for non-standard Turnkey consultancy for non-standard suggestions.suggestions.
• Consultancy for Process Audit & Yield Consultancy for Process Audit & Yield Improvement. Improvement.
• Consultancy for Proficient Plant Operations. Consultancy for Proficient Plant Operations.
Road Map: Road Map: Energy Conservation Energy Conservation ConsultancyConsultancy
1.1. Team formationTeam formation
2.2. Overview of Process & Operations Overview of Process & Operations
3.3. Analysis of Specific Energy ConsumptionAnalysis of Specific Energy Consumption
4.4. Energy Accounting & Balancing Energy Accounting & Balancing
5.5. Energy Consumers / Converters Energy Consumers / Converters
6.6. Distribution SystemsDistribution Systems
7.7. Utilization systemsUtilization systems
8.8. Identification of potential saving areasIdentification of potential saving areas
9.9. Implementation Implementation
10.10.Monitoring Monitoring
TEAMTEAM
• Participation of all concerned.Participation of all concerned.
• Positive suggestions through various schemes. Positive suggestions through various schemes.
• Immediate & correct evaluation of suggestions.Immediate & correct evaluation of suggestions.
• Positive solutions for roadblocks / problem Positive solutions for roadblocks / problem areas.areas.
• Wider acceptance for recommendation.Wider acceptance for recommendation.
• Quick and effective implementation. Quick and effective implementation.
• Development of knowledge bank. Development of knowledge bank.
• Continual improvements. Continual improvements.
• Savings on sustainable basis. Savings on sustainable basis.
Overview of Process / Overview of Process / OperationsOperations• Brief description of activities, with Brief description of activities, with
emphasis of major consumers. emphasis of major consumers.
• Process / Material flow diagram. Process / Material flow diagram.
• Utilization pattern for major consumers.Utilization pattern for major consumers.
• Co-relate the critical parameters at the Co-relate the critical parameters at the point of generation & utilizationpoint of generation & utilization– Air pressure at compressor outlet / point of Air pressure at compressor outlet / point of
utilization utilization – Suction pressure of refrigeration compressor Suction pressure of refrigeration compressor
/ process temperature / process temperature
Specific Energy Specific Energy Consumption Consumption
Specific energy is the energy consumed Specific energy is the energy consumed per unit output. per unit output.
Analyze variations with respect toAnalyze variations with respect to– OutputOutput– Seasonal variationsSeasonal variations– YieldYield
Start the analysis at Macro-level Start the analysis at Macro-level
then then
Proceed towards Micro-level Proceed towards Micro-level
ExampleExample
Specific Energy Specific Energy ConsumptionConsumption
20
22
24
26
28
30
32
34
1000 1050 1100 1150 1200 1250 1300 1350 1400
Production (kg/day)
Sp
En
ergy
(R
s/k
g)
Initial
Stage
Final
Ideal
Energy Accounting / Energy Accounting / Balance Balance Prepare break up of consumption for each Prepare break up of consumption for each
form of energy byform of energy by
– Measuring energy consumption of individual Measuring energy consumption of individual equipment.equipment.
– Noting down operating period.Noting down operating period.– Take data from various sub-metersTake data from various sub-meters
Compare total consumption as estimated Compare total consumption as estimated above with actual consumption to above with actual consumption to ascertain ascertain
– ““Unaccounted” or “Miscellaneous” portion of Unaccounted” or “Miscellaneous” portion of the consumptionthe consumption
Analyze consumption pattern (wrt time)Analyze consumption pattern (wrt time)
ExampleExample
Energy Accounting / Balancing Energy Accounting / Balancing Description Description %% kWh/MkWh/M
Illumination Illumination 30%30% 5,40,0005,40,000
Air conditioning Air conditioning 20%20% 3,60,0003,60,000
Computers Computers 7.5%7.5% 1,35,0001,35,000
PumpsPumps 12.5%12.5% 2,25,0002,25,000
Electrical Heating Electrical Heating 2.5%2.5% 45,00045,000
Residential & Commercial Residential & Commercial 15%15% 2,70,0002,70,000
Miscellaneous Miscellaneous 12.5%12.5% 2,25,0002,25,000
Total Total 100%100% 18,00,0018,00,0000
Energy Accounting Energy Accounting
Description Consumption kWh %
Residential & Commercial 270000 15.0%
Hostels 420000 23.3%Pumping 225000 12.5%Common Lighting 120000 6.7%Departments 765000 42.5%
Total180000
0 100.0%
Average Power (kW)Average Power (kW)Month Overall 22 to 6 6 to 9 &
12 to 189 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 / Energy Consumers / ConvertersConverters
Evaluate performance of major consumers toEvaluate performance of major consumers to
– Carry out energy balance for the entire system.Carry out energy balance for the entire system.– Check if the equipment operates at design Check if the equipment operates at design
capacity.capacity.– Estimate efficiency at design / operating capacity.Estimate efficiency at design / operating capacity.– Compute specific energy consumption.Compute specific energy consumption.– List the major losses and estimate their List the major losses and estimate their
contribution. contribution. – Discuss & finalize ways to eliminate / minimize Discuss & finalize ways to eliminate / minimize
the losses and optimize the efficiency /output.the losses and optimize the efficiency /output.– Evaluate possibility of enhancing useful output.Evaluate possibility of enhancing useful output.– Check feasibility of using cheaper source of Check feasibility of using cheaper source of
energy do the same work.energy do the same work.
Basic Definitions Basic Definitions
Efficiency: Efficiency: Ratio of Energy utilized for useful work to the Ratio of Energy utilized for useful work to the total energy supplied to the equipment. total energy supplied to the equipment.
Ratio of to energy supplied less sum of all Ratio of to energy supplied less sum of all losses to the total energy supplied to the losses to the total energy supplied to the equipment. equipment.
Capacity utilization:Capacity utilization:Ratio of the Actual output to the Rated output Ratio of the Actual output to the Rated output of the equipment.of the equipment.
Specific energy consumption:Specific energy consumption:Ratio of the total energy supplied to the Ratio of the total energy supplied to the equipment to the Actual output.equipment to the Actual output.
Specific Power Consumption – Specific Power Consumption – Shaft Power (kWh/TR)Shaft Power (kWh/TR)Evaporato
r 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)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 Air Compressor
Pr Sp Power Sp Output Power
Bar kW/M3 M3/kW kW
1 0.037 27.0 100
2 0.057 17.6 153.3
3 0.077 13.0 207.3
4 0.086 11.7 231.6
7 0.108 9.3 291.6
10 0.128 7.8 345.6
15 0.154 6.5 416.9
Distribution Systems Distribution Systems
• Utilities like steam are generated at Utilities like steam are generated at centralized place & distributed through out centralized place & distributed through out plant.plant.
• Such distribution is always associated with Such distribution is always associated with drop in energy level.drop in energy level.
• Distribution losses are such losses expressed Distribution losses are such losses expressed as fraction (or percent) of the initial energy.as fraction (or percent) of the initial energy.
• Such losses can be in in more than one form Such losses can be in in more than one form like pressure drop, heat gain, leakages, etc.like pressure drop, heat gain, leakages, etc.
• Minimizing such losses is one of the simplest Minimizing such losses is one of the simplest & surest way of conservation of energy. & surest way of conservation of energy.
ExampleExample
Distribution SystemsDistribution Systems
SteamSteam
• Insulation Insulation • LeakagesLeakages• Pressure drop Pressure drop
– RoutingRouting– Line size Line size
• TrappingTrapping– LocationLocation– Size Size – Type Type
Utilization Systems Utilization Systems
• Efficient utilization of utilities / energy is of prime Efficient utilization of utilities / energy is of prime importance.importance.
• Conduct energy balance for each form of energy.Conduct energy balance for each form of energy.
• Identify critical parameters for utilities.Identify critical parameters for utilities.
• Validate criticality of process / plant parameters.Validate criticality of process / plant parameters.
• Map process / plant requirement with generation Map process / plant requirement with generation for critical parameters.for critical parameters.
• Quantify waste streams and potential for energy Quantify waste streams and potential for energy recovery through the same.recovery through the same.
• Look for more economical source of energy.Look for more economical source of energy.
Plate Type Heat
Exchanger
Energy Recovery from Effluent Chilled Energy Recovery from Effluent Chilled WaterWater
Waste Ice 8.5 TPDWaste Ice 8.5 TPD Fresh Water 30Fresh Water 3000CC 221m221m33/day/day
Ch WaterCh Water 111100CC 25 2500C E T P C E T P Effluent Effluent
121200CC
221m221m33/day/day 1250 TR / 221 M1250 TR / 221 M33/day/day
131300C C
Process
Chilled Water System
Identification Identification ofof
Energy Saving AreasEnergy Saving Areas• Analyze the deviations from norms / Analyze the deviations from norms /
normal values.normal values.• Identify reasons.Identify reasons.• Work out corrective action.Work out corrective action.• Discuss with TEAM to formulate Action Discuss with TEAM to formulate Action
PlanPlan• Make simple but complete fact sheet for Make simple but complete fact sheet for
each area.each area.• Categorize areas based on ease of Categorize areas based on ease of
implementation, investment, etc.implementation, investment, etc.
Implementation Implementation
• Pick up low hanging fruits – it goes in a Pick up low hanging fruits – it goes in a great way to boost up team moral and great way to boost up team moral and management support.management support.
• Supervise actual implementation Supervise actual implementation
• Provide assistance during commissioning Provide assistance during commissioning & trouble-shooting. & trouble-shooting.
Monitoring Monitoring
• Ensure that the Team is on the right path Ensure that the Team is on the right path and at correct pace.and at correct pace.
• Measure the actual savings and ensure Measure the actual savings and ensure realization on sustainable basis.realization on sustainable basis.
• Devise monitoring system for key energy Devise monitoring system for key energy consumers & prepare log / data sheets.consumers & prepare log / data sheets.
• Install mechanism for suggestion scheme Install mechanism for suggestion scheme with effective implementation.with effective implementation.
• Monitor specific energy consumption at Monitor specific energy consumption at macro as well as micro level.macro as well as micro level.
In NutshellIn Nutshell1.1. Team formationTeam formation
2.2. Overview of Process & Operations Overview of Process & Operations
3.3. Analysis of Specific Energy ConsumptionAnalysis of Specific Energy Consumption
4.4. Energy Accounting & Balancing Energy Accounting & Balancing
5.5. Energy Consumers / Converters Energy Consumers / Converters
6.6. Distribution SystemsDistribution Systems
7.7. Utilization systemsUtilization systems
8.8. Identification of potential saving areasIdentification of potential saving areas
9.9. Implementation Implementation
10.10.Monitoring Monitoring
Thank Thank
You!You!
