Energy Efficiency for Materials and Manufacturing Industry in India

Rangan BanerjeeDepartment of Energy Science and Engineering

IIT Bombay

Invited talk at National Seminar Technology Thrusts on Materials & Manufacturing Sector in India, Kolkatta, July 28, 2016

Non-metallic minerals

10%

Paper, pulp and print

6%

Food and tobacco

5%

Non-ferrous metals

3%

Machinery

4%

Textile and leather

2%

Mining and quarrying

2%

Construction

1%

Transport equipment

1%

Wood and wood products

1%

Iron and Steel

20%

Others

16%

Chemical and Petrochemical

29%

World India

45%

0%

1%

1%

1%

1%

6%

7%

18%

20% Iron and Steel

Chemical and Petrochemical

Non-metallic minerals

Food and Tobacco

Paper, pulp an print

Textile and LeatherMining and Quarrying

Non-ferrous metals

Machinery

Others

Source: ETP, 2008

Share of industrial final energy use by different sectors in 2005

3

Total Material Production (Million Tons) - 2005

Regions Steel Cement Paper Ammonia Aluminium

US 95 101 91 10 2.5

China 355 1060 62 46.3 8.5

India 45 153 7 12 0.9

Brazil 31.6 36.7 10 0.95 1.4

South Africa 9.5 13 - 0.5 0.85

World 1146 2310 361 151 41

Regional Variation of Material Production in 2005

India (2012) 63 200 9.5 12 1.2

Industrial Energy Efficiency

Energy Conservation Opportunities

Design Stage –

Efficient process design

Efficient equipment design/ selection

Efficient Utility System design

Operating Decisions-

Energy Auditing

Operating Strategies

Retrofit equipment

Replace equipment/processes

DEFINE AUDIT OBJECTIVES

QUESTIONNAIRE

REVIEW PAST RECORDS

WALK THROUGH / PLANT FAMILIARISATION

DATA REQUIREMENTS

MEASUREMENTS / TESTS

COMPUTE MASS / ENERGY BALANCES

ENUMERATE ENERGY CONSERVATION OPPORTUNITIES

EVALUATE ECOs

PRIORITISE RECOMMENDATIONS

DATA ANALYSIS

INSTALL MEASURES

Sankey Diagram for a Cement Plant

ISO 50001:2011 Requirements with guidance for use

Voluntary International Standard

8

http://www.iso.org/iso/iso_50001_energy.pdf

Not feasible to define a single norm/standard unless there is significant homogeneity amongst units in a sector

Energy efficiency improvement targets would have to be almost“unit specific”

Bands of differential targets to be created within sectors

Each DC mandated to reduce its SEC by a fixed percentage, based on its current SEC within the sectoral bandwidth

Setting Energy Consumption Norms

Source: DG BEE presentation

Target

Baseline SEC

Target SEC

Achieved SEC

Scenario 1

Scenario 2

Compliance

Issued Escerts

Purchase Escerts

Penalty

PAT - Energy Savings Certificates - incentivize actions

Source: DG BEE presentation

Metals 2010Annual Production

2010Per capita consumption

Avg.SEC India

Global Average

BAT

Aluminium

AluminaProduction

4.88 Million Tonnes

29.6 GJ/t

16 GJ/t 7.4 GJ/t

Aluminium 0.62 Million Tonnes

1.3 kg 14.5 kWh/kg

14.6kWh/kg

13.4 kWh/kg

Zinc 0.53 Million Tonnes

0.46 kg --- 23.6 GJ/t

15.2 GJ/tonne

Copper 0.63 Million Tonnes

0.55 kg ---- 13.8 GJ/t

7.4 GJ/tonne

Lead 0.31 Million Tonnes

0.27 kg --- ___ __

Source: India Minerals and Metals Forum 2012 – Ferrous + Non FerrousUNIDO, 2010

Key Non Ferrous Industry

Conservation Supply Curve - Steel

Policy Implications of Greenhouse Warming: Mitigation, Adaptation, and the Science Base , National Academy Press 1992

CSC for electricity in EU industry

http://www.isi.fraunhofer.de/isi-wAssets/docs/e/de/publikationen/5376_Fleiter.pdf

Co- Benefits

India Abatement Curve

Source: McKinsey

https://www.worldsteel.org/publications/factsheets/content/02/text_files/file0/document/fact_energy_2016.pdf

Global SEC Steel

Benchmark curve for Ammonia

Source: Beck , 2001

Thermodynamic Limits

Coal and coal products (21.5)

Crude, NGL, petroleum prod.

(13.6)

Natural gas (18.1)

Renewables (7.5)

Product

(44.6)

Loss

and

waste

(43.0)

Global

industrial

sector

Electricity (22.3)

Heat (4.6)

Total (87.6) Total

(87.6)

Coal and coal products (21.5)

Crude, NGL, petroleum prod.

(13.6)

Natural gas (18.1)

Renewables (7.5)

Product

(25.1)

Loss

and

waste

(59.2)

Global

industrial

sector

Electricity (22.3)

Heat (1.3)

Total (84.3) Total

(84.3)

Units in ExaJoules

Efficiency 51% Efficiency 30%

Energy Exergy

Source: Rosen, GEA

Energy Efficiency: Model Based Benchmarking

Glass Furnace -Model flow diagram

Mass of air

Flue gas leakage

Oxygen % at

regenerator outlet

De

sig

n

va

riab

les

Guess for total

heat added

Fuel

stoichiometric

calculation

Glass reaction

calculation

Furnace air / flue gas

leakage calculations

Gap in flux line Gap near burner

Furnace operating pressure

Cooling air velocity

Number of burner

Burner air nozzle

diameter

Furnace design capacity

Melting area

Furnace design details

Color of glass

Furnace geometry

Air leakage

Regenerator

calculationFlue gas outlet

temperature

Heat loss from flue

gas

Heat loss from

regenerator wall

Oxygen % at furnace

outlet

Combustion

zone

stoichiometric

calculation

Furnace

wall lossesFurnace operating

characteristics

Heat of

reaction and

heat carried

by glass

Mass of flue gas

Heat loss from

furnace area wall

Gas from glass

reaction

Raw material composition

Furnace

geometry

calculation

Furnace design

characteristics

Heat carried with glass

Heat of reaction for glass

Heat loss batch gas

Heat loss from batch

moisture

Total

heat

added

in

furnace

Fuel calculationFuel calorific

value

Fuel composition

Glass composition

Moisture in batch and

cullet

Cullet %

Glass draw

Fuel consumptionCombustion species

Heat loss from flue

gas leakage

Heat loss from air

leakage

Ambient conditions

Glass outlet

temperature

Port neck

Checkers

packing

Glass level

1

2

5

Manual damper for

airflow selection and

control

6

7

Diverter

damper

3

4

8

Measurement locations

Combustion air

Furnace measurement

Measurementlocation

Type of measurement

1Oxygen % , Pyrometer checkers surface temperature

2Oxygen %, Flue gas temperature

3Oxygen %, Flue gas temperature

4Oxygen %, Skin temperature

5Pyrometer checkers surface temperature

6Velocity of air at the suction of blower

7Outside wall temperature for crown and side wall

8Pyrometer glass surface temperature

28

Model results: Actual SEC

2.8%(118)

0.7%(30)69

1%(45)

9.7%(414)

38.2 % (1628)

2%(84)6.1%

(261)5% (212)

4.6% (198)

29.4%(1256)

33.8%(1485)

69% (2939)

Heat carried in glass

Furnace wall losses

Heat lost in moistureHeat of glass

reaction

Batch gas losses

Heat loss from furnace opening

Heat lost steel superstructure

Regenerator wall losses

Heat loss from flue gas

Heat lost in cold air ingress

Heat recovery in air heating

100%(4267)

Energy introduced in furnace

From fuel 134% (5752)

Heat carried in regenerator from flue gas

0

2000

4000

6000

8000

10000

12000

14000

16000

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Furnace number

SE

C (

kJ

/kg

)

Target SEC Actual SEC

Technology Options

Generic options – Motor drive systems, Compressed air systems, Steam systems

Cogeneration

Waste Heat Recovery – Heat Pipes,Heat Wheels, VARS, Heat Pumps

Pinch and Process Integration

Process Modifications – Specific Technology options

Renewable Energy Use

Carbon Capture and Storage

Next Practices

COREX, MIDREX, Hyl, HiSmelt, Itmk3 –New processes -

Oxy- fuel combustion – Zero Emission kiln

Zeman & Lackner,2006

Marginal Abatement curve – I&S

Source: Gordon et al,2014

Marginal Cost Energy Saved

Source: Gordon et al,2014

Energy Intensity of Iron

Source: Gordon et al,2014

Energy Intensity of Hot Rolled steel

Source: Gordon et al,2014

Industry Flows

Source: Marechal, GEA

Renewables in Industry

2005 share 9 % Globally

Biomass, solar thermal solutions

Possible to change mix to significantly increase renewables

Biomass – thermal applications – 1-2 year paybacks

Solar process heat 4-6 years

36

Schematic of Updraft Gasifier

Source: Cosmo Powertech Pvt. Ltd, Raipur

Gasifier efficiency 75%Biomass calorific value 3400

kcal/kgProducer gas burner efficiency

70%Temps upto 1000 C

37

Indian Case Studies

Steel Reheating Furnace Raipur Investment 3.75 million Rs, Annual savings 3.0 million Rs Simple Payback period 1.25 years, IRR 80% (IITB, Cosmos) (Rice Husk, wood) 1.25 Mkcals/hr

NARI, Sugarcane Leaves, Bagasse, Ceramic Tile furnace 0.25 Mkcals/hr

Silk Drying – TERI, payback period 2.5 years

• Carbon Dioxide Manufacture – GEDA, Cosmos• Biomethanation – 1 MW

38

Source: Kedare , ICORE 200539

Solar energy in industries

Metal industry – Zinc, aluminium, iron, silicon, magnesium

Lime production

Fullerenes and carbon nanotubes

Solar thermochemical process for zinc production

Deepak and Banerjee, 2016

300 kW pilot plant at WIS, Israel

Wieckert et al. 2007

Solar chemical plant for zinc production at WIS, Israel

Wieckert et al. 2007

Solar lime production

Meier et al 2006

Licht S, Wu H, Hettige C, Wang B, Asercion J, Lau J, et al. STEP cement: Solar Thermal Electrochemical Production of CaO without CO(2) emission. Chem Commun (Camb) 2012:6019–21. doi:10.1039/c2cc31341c.

Material Efficiency

45

Material Choice

46Allwood et al, 2011

Material Choice

47Allwood et al, 2011

48

Approaches

Benchmarking, Best practices

Dematerialisation, Redesign of product

Next Practices - Consortium approaches – Long term R&D

Grand Challenges – Innovations

Prototypes/ Demonstrations

Designer materials – Nano Technology, Bio-inspired materials

Future industrial growth- zero carbon growth

Acknowledgement

Balkrishna SurveDeepak YadavProf. Vishal SardeshpandeCTARA

Thank you

References

S.Khurana, R.Banerjee, U. N. Gaitonde, Applied Thermal Engineering, Vol22, p485-494,2002 E. Worrell,Potential for Improved Industrial Energy Use andMaterials,Ultrecht,1994 Allwood, JM and Ashby, MF and Gutowski, TG and Worrell, E (2011) Material efficiency: A white

paper. RESOUR CONSERV RECY, 55. pp. 362-381. ISSN 0921-3449 Allwood, JM and Ashby, MF and Gutowski, TG and Worrell, E (2013) Material efficiency:

providing material services with less material production. Philos Trans A Math Phys Eng Sci, 371. 20120496-. ISSN 1364-503X

Rangan Banerjee et al: Chapter 8 - Energy End Use: Industry. In Global Energy Assessment -Toward a Sustainable Future, Cambridge University Press, Cambridge, UK and New York, NY, USA and the International Institute for Applied Systems Analysis, Laxenburg, Austria

UNIDO, 2010: Global Industrial Energy Efficiency Benchmarking-An Energy Policy Tool, Working Paper, United Nations Industrial Development Organisation (UNIDO), November, 2010.

Yadav and Banerjee, 2015: Yadav D, Banerjee R. A review of solar thermochemical processes. Renew Sustain Energy Rev 2016;54:497–532. doi:10.1016/j.rser.2015.10.026.

Wieckert et al. 2007 : Wieckert C, Frommherz U, Kraupl S, Guillot E, Olalde G, Epstein M, et al. A 300 kW Solar Chemical Pilot Plant for the Carbothermic Production of Zinc. J Sol Energy Eng 2007;129:190–6. doi:10.1115/1.2711471.

Meier et al 2006: Meier A, Bonaldi E, Cella GM, Lipinski W, Wuillemin D. Solar chemical reactor technology for industrial production of lime. Sol Energy 2006;80:1355–62. http://dx.doi.org/10.1016/j.solener.2005.05.017