Energy Services (P) Ltd. ENERGY EFFICIENCY PRACTICES IN VARIOUS SECTORS

Transcription

1 Energy Services (P) Ltd. ENERGY EFFICIENCY PRACTICES IN VARIOUS SECTORS

2 Background PGS ENERGY SERVICES PVT. LTD established in 1997 as Accredited Energy Audit firm & ESCO for various energy efficiency/conservation projects of Industry, Commercial buildings & MCs. Our areas of expertise includes a broad spectrum of consultancy & Implementation of EC projects. PGSEPL is also registered as Micro Small & Medium Enterprise with NSIC Empanelment : BEE UNDP EESL SIDBI PEDA HAREDA GEDA MEDA H.P SDA Odisha SDA ASDA AAI DRDO Chandigarh Admin PAT : Since 2007 Cement, Textile, Iron & Steel, Chlor-Alkali, TPP, Pulp & Paper, Fertilizer EAs : BEE EESL NESTLE HAFED AAI PEDA SDAs HOSPITALS HOTEL 2009 : Successfully Implemented 1 st LED Street light project in India Jan Marg, Chd & Majitha PB IGEAs & ESCO : Chandigarh Administration SDAs RENEWABLE : Solar Projects Punjab & Haryana Raj Bhawan Judicial academy Chd Pb. Civil Sectt. Haryana assembly, U.T Sectt. Chd.

3 Cement ACC Limited Ambuja Cements ltd, Ropar Ambuja Cements ltd, Darlaghat Birla Corporation ltd HeidelbergCements India Ltd JK cement Works Chanderia Cement Works Paper & Pulp Satia Industries Ltd BILT Papers Ltd Bindals Papers Mills Ltd Yash Papers Ltd Ruchira Papers ltd Dev Priya Products Ltd Naini Tissues Ltd Shree Shyam Paper Mills Textile: Vardhman Group Winsome Yarns Ltd. Reliance Industries Limited Grasim Industries Arvind Ltd. Birla Century Ashima Ltd. Spin fab Ashima Ltd. Denim Hisar Spinning Mills Soma Textiles & Industries Rainbow Denim Ltd. Suzuki Synthetics Pvt. Ltd Suzuki Suitings Ltd. Shree Rajasthan Syntax Ltd. BMD Pvt. Ltd.

4 Fertilizers IFFCO, Gujarat IFFCO, Odisha FACT, Kerela SPIC, Tamil Nadu Madras Fertilizers ltd GSFC, Sikka GSFC, Vadodara GNFC, Gujarat Mangalore Chemicals & Fertilizers Ltd. Rashtriya Chemicals Ltd. Paradeep Phosphates ltd SIEL Chemical Complex Tata Chemicals ltd National Fertilizers ltd Coromandel International Ltd. Vizag Coromandel International Ltd. Tamil Nadu Deepak Fertilizer & Petrochemicals Corpn. Ltd. Kanpur Fertilizers & Cement Ltd. Iron & Steel Anjani Steels ltd Singhal Enterprises ltd Top Worth Iron & Steel Crest Steel & Power Thermal Power plant Yamunanagar TPP Panipat TPP NTPC Ltd.

5 Contents 1. Case Study: Pulp & Paper Sector Strategies for EE & ENCON Approaches 2. Case Study: Cement Sector EE with zero investment 3. Case Study: Building EE project ESCO project 4. Case Study: Iron & Steel Sector Optimization Strategies for EE

6 Case Study: PULP & PAPER INDS. Satia Paper Mills, Muktsar (Punjab) Energy Efficiency strategies adopted: Achievements Quantified 1. Modification in Paper machine (press and wire part) 3350 Mtoe a. Steam saved = 9900 tonne (annual) ~ 10% 936 Mtoe b. Fuel saved = 2600 tonne/yr c. Dryness = 3% increase d. Production = 6 tonne/day increase~1980t/yr 1736 Mtoe e. M/c Speed = 50 rpm increase ~ 51% of more Press part modification for enhanced water removal Hydronip, Hydraulic pistons Press Roller Change

7 Contt. Energy Efficiency strategies adopted: 2. Modifications in Vaccum pumps mtoe a. Header modifications 100 kw b. Pump/ Motors replacements 345 kw c. Shutting OFF 3 vaccum pumps (usage = 1 pump) 3. Commissioning of H.P Boiler (490 C) Achievements Quantified 8.6 mtoe a. increase in evaporation ratio = 3.8 to 3.9 t/t b. fuel saved = 3.16 % ~ 4189 tonne/yr Total savings mtoe

8 Case Study: PULP & PAPER INDS. Ruchira Paper Mills ENCON Approach Benefits/ savings 1. Close loop arrangement for bucket elevator Rs. 7.5 lacs energy cost/yr BENEFITS: a. Furnace efficiency improvement 0.14% b. ID Fan load reduction 84 KWH per day c. Steam saved 39 tonne per day d. Manual labour cost cutting Rs monthly e. Fuel saved 0.5 tonne per day ENERGY SAVINGS 2.6MTOE

9 Contt.. ENCON Approach (Year 2016) Benefits/ savings 2. Heat Exchanger (3 no.s) ~ Black liquor Rs crores~year 1 a. Temp recovered 85 C b. RO water temp increase 35 C c. Steam saved 80 tonne/day d. Total savings 6.96 MTOE Initial and present scenario comparison Energy Consumption before Heat exchanger mkcal Energy Consumption after Heat exchanger mkcal SAVINGS mkal

10 Case Study: Cement Sector Ambuja Cement, Ropar (Punjab) Energy Conservation measures Savings Achieved Increase of biomass usage in place of coal (16 % to 40%) 43,461 mtoe a. Optimisation of excess air in boilers (33% to 30%) 3083 mkcal b. Improvisation in CHP, saving in electrical power 984 mkcal f for coal crushing & Grinding c. Sensible heat savings due to lower flyash (3965 tonne ash) 3230 mkcal Installation of sonic soot blower~dislodging ash deposit 30,521 mtoe a. Energy savings mkcal b. Decrease in fuel consumption 2% approx.

11 Contt. Energy Conservation measures Bottom Ash draining via bed ash cooling ~ recover sensible heat from hot bed material Savings Achieved 92,020 mtoe a. heat loss savings in bottom ash (coal) 133 kcal/kg coal b. heat loss savings in bottom ash (biomass) 45 kcal/kg biomass Improvisation in packing plant/ interlocking in bucket elevator mtoe Rs crores a. Increase in production 11 MT/hr b. Reduction in electrical power consumption kwh c. Reduction in running hours Hrs. Improvement = arresting air leakages + stopping the idle running during shift change +extraction blockage cleaned in silo

12 Case Study: Cement Sector Diamond Cement Ltd. HCIL, Damoh Energy Conservation measure adopted Energy Savings 1. Installation of WHR System 1,01,146 mtoe Benefit: a. Recovery of waste heat from 3 kilns C Recovered b. Energy Savings Mio kwh c. Annual Cost savings Rs. 784 millions Investment Rs millions Payback 2.4 years

13 Case Study: Building ESCO Project As part of an initiative to reduce energy cost and consumption, SDA secured the services of PGS Team to perform an energy audit and prepare a detailed project report of Office Building in an effort to develop com prehensive Energy Conservation and Retrofit Measures (ECRMs). Previous & Present Annual Energy Consumption Scenario Previous Present Type Annual Energy consumption (kwh) Type Annual Energy consumption (kwh) T-12 Double Fixture W*2 LED Tube Light T-12 Single Fixture W LED Tube Light Old Ceiling Fan BEE five Star Rated Ceiling Fan Old 1.5TR Split AC BEE five Star Rated 1.5 TR Split AC Total Total 32634

14 Case Study: Office Building Energy Savings in terms of MTOE & Avoided Capacity Generation As a result of implementation of the aforementioned ECRMs, the state would be able to avoid a capacity addition (MW) to cater this reduction of load. This is calculated in terms of Avoided Capacity Generation (MW) using the formula given below: Total Annual Energy Savings : 16,055 kwh Avoided Capacity Generation for SDA Building (in MW) = MW MTOE savings = 1.38 Impacts on reduction of Green House Gases (GHGs) Co2 equivalent

15 Case Study: Steel Industry Singhal Entreprises Ltd. Energy Efficiency strategies adopted: Achievements Quantified 1. Reduction of LOI content Rs lakhs Benefits: a. Unburnt Carbon loss reduction in ash 4.97 to 3 % b. Reduction in coal consumption 3 % c. Improvement in boiler efficiency 3-4 % Technology used~air velocity, uniform raw material size 2. Reduction in bends~steam line to header Rs. 84 lakhs a. Reduction in pressure drop 4 kg/cm2 b. Fuel savings 3%

16 Case Study: Steel Industry Anjani Steels Ltd. Optimization techniques for EE Savings Quantised 1. De-staging of Boiler Feed Pump Kwh Rs. 9.5 Lakhs Removing one stage (From 11 to 10 no.) ~ Discharge Pressur e reduction by 6 kg/cm 2 (90Kg/cm 2 to 84Kg/cm 2 ) Investment of 1 lac 20kWh Payback=1 month 2. Rectifying & Repairing the Leakages at SMS Compressor Kwh Rs Lakhs a. Power saving 1 kwh per leakage b. Zero investment Immediate payback

17 Contt Optimization techniques for EE 3. Improvement in Economizer & Air Preheater Efficiency by Cleaning the Tubes & Plugging the Leakages a. Heat loss saving due to air ingress Savings Quantised Rs Crores b. Coal consumption reduction (3744 tonne) 5 % No investment 4. Reducing the Unload Set Point Pressure at Rolling Mill Compressor Payback= Immediate 60480kWh Rs Lakhs a. Power Savings 12 kwh b. Pressure reduction (8Kg/cm2 to 7.5Kg/cm2) No investment Payback= Immediate

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