Agenda. Two Examples from Sports. Olympic Gold Medal Winners in High Jump. CII Sohrabji Godrej Green Business Centre, Hyderabad. Energy Conservation

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1 Energy Conservation CII Sohrabji Godrej Green Business Centre, Hyderabad A unique Public Private Partnership ( CII, Govt of Andhra Pradesh, USAID and Pirojsha Godrej Foundation ) Opportunities in Boilers & Steam system Centre of Excellence for Energy, Environment, Green Buildings, Renewable energy, Water & Climate change activities in India Agenda v Approach for energy conservation Example from sports v Opportunities for energy efficiency Two Examples from Sports v Sergei Bubka - Ukranianpole vaulter q I person to cross 6-m mark q Continuously improved q Broke his own records > 14 times! improvement Case studies Efficiency Improvement - Continuous Olympic Gold Medal Winners in High Jump 2.6 Inference from Sports 2.4 Fosbury Flip v Fosbury Scissors Western Roll Straddle q Basically a Gymnast - Not successful q Applied principles of Gymnastics to High Jump 1.8 q Result - A Quantum Jump!!! Adopt the Latest Technology 1.6 Inputs from Other Industries - Innovation Source: Pascale

2 Arrest air infiltration through APH Unit I ESP 6.7 % O 2 Few Case Studies 4.6 % O 2 APH 2.3 % O 2 ESP 6.8 % O 2 Q M3/s H 406 mm M 725 kw Observation - Air infiltration in Air Preheater v Online flue gas analyzer available Before & after air pre heater v Combustion analysis carried out Using portable combustion analyser Unit 1 APH -A APH -B Inlet Outlet Inlet Outlet % O Air infiltration in Air Preheater Unit 2 APH -A APH -B Inlet Outlet Inlet Outlet % O % CO CO (ppm) Temp o C % CO CO (ppm) Temp o C Air infiltration in Air Preheater Air infiltration in Air Preheater X Kg of air 20.9 % O 2 v Unit 1 quantity of air ingress is significant 1 Kg flue gas 2.3 % O 2 Air preheater 1+ X Kg of Flue gas 4.6 % O 2 v Unit -1 due for maintenance v Arrest air preheater leakage during the maintenance v Quantity of air infiltration Unit -1 APH - A % APH B % Unit 2 APH A % APH B % v Online monitoring available before & after APH Periodically cross check using portable analyser v Equivalent coal saving tons/hr

3 Methods for reducing air infiltration in flue gas side Ceramite coating in the bends v Holes in ID fan duct bends & corners Erosion due to flue gas especially in locations where direction of flow changes v Increased air infiltration & hence increased ID fan power consumption Castable refractory for reducing Erosion Methods for reducing air infiltration in flue gas side v Covered with Thermal Fabric Expansion Special material-can withstand temperature upto o C Sandwiched with Glass Wool Can be installed ON line 2.Operate the condenser at design v What is the effect of vacuum on turbine performance? v Turbine capacity - 37 MW v Present load - 15 MW loaded less than 50% of the capacity v During normal operating condition very low vacuum has been achieved Achieved vacuum kg/cm 2 (a) Design vacuum kg/cm 2 (a) Operate the condenser at design v Effect of lower vacuum compared to design v Life of the turbine Reduction in dryness fraction of exhaust steam q Turbines normally designed for 0.86 dryness fraction Increased pitting on LP turbine blades v Increase in energy consumption Velocity of steam flow increases Exhaust loss increases

4 Turbine Exhaust loss curve Operate the condenser at design Pressure (kg/cm 2 ) Velocity (m/sec) Exhaust loss kcal/kg Operate the condenser at design v The exhaust loss is the lowest at 0.08 kg/cm 2 (a) vacuum v How to maintain the design vacuum Reduce the quantity of water supply Optimise the operation of cooling tower fan Control on Ejector v Equivalent reduction in steam consumption kg/hr Annual Saving - Rs Lakhs 3. High efficiency Micro turbine v Waste heat recovery boiler in operation v Operating steam parameters Pressure - 38 kg/cm 2 Saturated steam Capacity tons/hr v Steam utilised for turbo driven circulating water pump & exhaust steam for process High efficiency Micro turbine v Power generation potential partially utilised v Specification of circulation water pump Flow m 3 /hr Head m v Power requirement - 60 kw Power generation potential v Conventional turbine with exhaust in superheated condition Turbine single stage v Power generation potential 75 kw v Latest double stage turbine gives excellent potential Power generation opportunity kw

5 Steam and Power Costing Power generation potential Pr 38 kg/cm 2(g) Temp sat Flow 12 tons/hr 500 kw v Supplier guaranteed upto kw v Existing circulation water pumps needs to Two stage turbine ~ be electrical motor driven Pr 5 kg/cm 2 (g) Temp 158 oc Dryness fraction 0.93 v Net power generation kw Excellent potential for power generation Annual Saving - Rs Lakhs Investment - Rs Lakhs Payback period - 8 months 4.Steam Ejector / Vacuum Pump Install vacuum pump in lieu of steam ejector v Presently steam ejector is in operation Existing Steam v Design specification Working steam pr - 10 ata Condenser or vessel CW Proposed Steam ejector Steam temperature o C Steam consumption kg/hr Suction pressure ata Capacity of dry air kg/hr Water ring vacuum pump Dry air + water vapour kg/hr Install vacuum pump in lieu of steam ejector v Main steam utilised as auxiliary steam v From the turbine characteristic curve Power generation potential for 1 ton/hr of steam -250 units v Install vacuum pump in lieu of steam ejector v Vacuum pump specification Pressure mmhg Capacity m 3 /sec v Estimated power consumption - 47 kw Install vacuum pump in lieu of steam ejector v Temperature gain in ejector condensor - 10 o C v Increase in steam consumption in deaerator - 1 ton/hr steam at 5.5 kg/cm 2 v Reduction in power generation units/ton v Net benefit kw Annual Saving - Rs Lakhs Investment - Rs 15 Lakhs Payback period - 4 Months

6 5. Install Thermo compressor and recover flash steam from feed tank v Condensate from digester Collected in feed tank v Heat balance of feed tank and estimation of flash steam quantity indicate q Flash steam quantity is about 2.55 tons/hr Water in feed 0.3 kg/cm TPH Flash Steam to atomos phere (Y) kg Flash vessel Install Thermo compressor and recover flash steam from feed tank Motive 33 kg/cm 2 (abs) Temp 390 o C Flow 1.5 tons/hr (approx) LP 0.1 kg/cm 2 (abs) Temp 100 o C Flow 2.0 tons/hr Discharge 2.5 kg/cm 2 (abs) Flow 3.5 tons/hr 98 C Condensate (1 Y) kg Install Thermo compressor and recover flash steam from feed tank v Good potential to recover the flash steam v Best option - Installing thermo compressor and injecting back to low pressure header To sum up vtremendous potential for Energy Saving in Boilers & Steam systems vbecome a world class energy efficient unit Implement the latest technologies Annual saving - Rs Lakhs Investment - Rs Lakhs Payback - 13 Months Learning the best practices from other sector / industries Contact S Karthikeyan Senior Counsellor CII-Sohrabji Godrej Green Business Centre Confederation of Indian Industry Southern Regional Headquarters 98/1 Velacherry Main Road, Guindy Chennai s.karthikeyan@cii.in Mobile : Website : / Thank You