GIZ KAEFER PPP. Energy-Efficiency - moving India's towards a sustainable future. Jakob Brueckner

Transcription

1 GIZ KAEFER PPP Energy-Efficiency - moving India's towards a sustainable future Jakob Brueckner Page Seite 1

2 Objectives & Partners Main objectives are to provide industries access to: Advisory service and training Financial products that enable them to implement energy efficient insulation And to raise the awareness on the competitive advantages of integrating sustainable measures into their operations Main partners: German International Cooperation KAEFER Punj Lloyd Ltd. (KPLL) India Bureau of Energy Efficiency (BEE) Jakob Brueckner Page Seite 2

3 Project Overview Identify and prioritize target sectors in India Install insulation on two pilot plants > Easily replicable results > Quantifiable payback > Owner consent for a brief plant shutdown needed Set CSR measures Make financial products available Awareness raising campaign through: > Training, energy bus > Seminars, associations Jakob Brueckner Page Seite 3

4 BEFORE INSULATION Heat loss to atmosphere Heat (H) Hot Surface 1. Loss of energy 2. Burn Injury Risk Heat flow Seite 4 Page 4

5 AFTER INSULATION Heat loss prevention due to insulation Cold Surface 1. Cost Saving 2. Improved Safety Heat flow Seite 5 Page 5

6 Common scene in industry Seite 6 Page 6

7 Insulation as cost effective strategic Seite 7 Page 7

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9 Final selection of pilot plant Pulp & Paper industry Paper machine: Drying process Selected as pilot project because: Significant energy saving Cost savings very attractive and quantifiable Only short plant shut down for insulation implementation necessary Very high replication potential Seite 9 Page 9

10 The drying process Seite 10 Page 10

11 Challenges and solutions in the drying process Challenges: Rotating at rpm Normally industries insulate with glass/mineral wool Water resistance very low Insulation peel off within 2-3 month Promote corrosion Solution: Resin bounded mineral wool slabs Water vapor resistance factor: 1 Chemically neutral, neither cause nor promote corrosion Seite 11 Page 11

12 Economic savings and payback time Drying Drums, Nos 38, Ø1.5m, No 1, Ø 4.5m Total not insulated area: 128m 2 Temperature: 105 C What is the impact if this drums were insulated up to the latest standards: Investment: Rs. 420,000 Cost Savings: Rs. 855,000/ Year Payback time: 6 Month Seite 12 Page 12

13 Economic savings and payback time Drying Drums, Nos 38, Ø1.5m, No 1, Ø 4.5m Total not insulated area: 128m 2 Temperature: 105 C What is the impact if this drums were insulated up to the latest standards: Investment: Rs. 420,000 Cost Savings: Rs. 855,000/ Year Payback time: 6 Month Seite 13 Page 13

14 Economic savings and payback time Drying Drums, Nos 38, Ø1.5m, No 1, Ø 4.5m Total not insulated area: 128m 2 Temperature: 105 C What is the impact if this drums were insulated up to the latest standards: Investment: Rs. 420,000 Cost Savings: Rs. 855,000/ Year Payback time: 6 Month Seite 14 Page 14

15 Further advantages Enhancing paper machine production capacity (5-10%) Improve paper output quality Improved personal protection for workers Reduce ambient temperature in the workshop Easily replicable for other paper mills Seite 15 Page 15

16 INSULATION OF DIGESTERS Before Insulation: 1. Average Ambient Temp C 2. Average Surface Temp C 3. Total area insulated m2 4. Cost of Heat Loss - Rs Rs/million Kcal. 5. Running Hr / Yr. 6. Average cost of Heat Loss - Rs.21,80,250 /year After insulation: 1. Average Surface Temp C 2 Total Savings - Rs. 17,84,250/year 3. Insulation Thickness - 50 mm Mineral wool -128 kg/m3 density. 4. Total cost of insulation - Approx. Rs. 2,50, Average pay back period - 2 Months Seite 16 Page 16

17 INSULATION OF DIGESTERS Before Insulation: 1. Average Ambient Temp C 2. Average Surface Temp C 3. Total area insulated m2 4. Cost of Heat Loss - Rs Rs/million Kcal. 5. Running Hr / Yr. 6. Average cost of Heat Loss - Rs.21,80,250 /year After insulation: 1. Average Surface Temp C 2 Total Savings - Rs. 17,84,250/year 3. Insulation Thickness - 50 mm Mineral wool -128 kg/m3 density. 4. Total cost of insulation - Approx. Rs. 2,50, Average pay back period - 2 Months Seite 17 Page 17

18 Some Revealing Facts As per IS: 14164: Seite 18 Page 18

19 Jakob Brueckner Page Seite 19