Energy Benchmarking for Non Ferrous Industry in India. Rangan Banerjee Department of Energy Science and Engineering IIT Bombay

Transcription

1 Energy Benchmarking for Non Ferrous Industry in India Rangan Banerjee Department of Energy Science and Engineering IIT Bombay International Conference on Energy and Environmental Issues in Non Ferrous Industries, Kolkata, December 7-8, 2012

2 Motivation Increase in energy prices fuels, electricity Control costs energy significant and growing component of production cost Climate change Greenhouse gas carbon footprint 2

3 $/BBL Crude Oil Price Variation Average monthly price data from July 1988 to October 2012 Source: last accessed on Dec 3,

4 DEFINE AUDIT OBJECTIVES QUESTIONNAIRE REVIEW PAST RECORDS WALK THROUGH / PLANT FAMILIARISATION DATA REQUIREMENTS DATA ANALYSIS MEASUREMENTS / TESTS COMPUTE MASS / ENERGY BALANCES INSTALL MEASURES ENUMERATE ENERGY CONSERVATION OPPORTUNITIES EVALUATE ECOs PRIORITISE RECOMMENDATIONS 4

5 Industry Flows Source: Marechal, GEA 5

6 Energy Conservation Options Waste Heat Recovery Equipment Retrofits Replace equipment Cogeneration/ Efficient utility systems Pinch Analysis/ Process Integration Renewables Process Improvements/ New Processes 6

7 What is Energy Benchmarking? Comparision and target setting of energy performance Specific Energy Consumption Variations due to scale, age, process, raw materials, environment Statistical Benchmarking Zero Based Benchmarking (Thermodynamics) Model Based Benchmarking 7

8 Thermodynamic Limits Coal and coal products (21.5) Crude, NGL, petroleum prod. (13.6) Natural gas (18.1) Renewables (7.5) Electricity (22.3) Heat (4.6) Total (87.6) Global industrial sector Energy Product (44.6) Loss and waste (43.0) Total (87.6) Coal and coal products (21.5) Crude, NGL, petroleum prod. (13.6) Natural gas (18.1) Renewables (7.5) Electricity (22.3) Heat (1.3) Total (84.3) Units in ExaJoules Global industrial sector Exergy Product (25.1) Loss and waste (59.2) Total (84.3) Source: Rosen, GEA Efficiency 51% Efficiency 30% 8

9 Key Non Ferrous Industry Metals 2010 Annual Production 2010 Per capita consumption Avg. SEC India Global Average BAT Aluminium Alumina Production Aluminium 4.88 Million Tonnes 0.62 Million Tonnes 1.3 kg 14.5 kwh/kg 29.6 GJ/t 16 GJ/t 7.4 GJ/t 14.6 kwh/kg 13.4 kwh/kg Zinc 0.53 Million Tonnes 0.46 kg GJ/t* 23.6 GJ/t 15.2 GJ/tonne Copper 0.63 Million Tonnes 0.55 kg GJ/t 7.4 GJ/tonne Lead 0.31 Million Tonnes 0.27 kg Source: India Minerals and Metals Forum 2012 Ferrous + Non Ferrous UNIDO, 2010 Hindustan Zinc Limited Presented by Akhilesh Joshi, Chief Operating Officer * Data of Rampura Agucha Mine (Largest Zinc Mine in India) 9

10 Industrial Energy Use Trend Share of industrial final energy use by different sectors in 2005 World India Wood and wood products 1% Transport equipment 1% Construction 1% Mining and quarrying 2% Others 16% Chemical and Petrochemical 29% Others 45% 20% Iron and Steel Textile and leather 2% Machinery 4% Non-ferrous metals 3% Food and tobacco 5% Paper, pulp and print 6% Iron and Steel 20% 0% Machinery Non-ferrous metals Mining and Quarrying 1% 1% Chemical and Petrochemical 18% 7% Non-metallic minerals 6% Food and Tobacco 1% Paper, pulp an print 1% Textile and Leather Non-metallic minerals 10% Source: ETP,

11 Source: UNIDO,

12 Source: UNIDO,

13 Source: UNIDO,

14 Source: Beck,

15 Source: UNIDO,

16 Source: UNIDO,

17 Generalized approach for model based benchmarking Survey of existing models of process Developing experimentation protocols Energy intensive process Understanding basics Defining system boundary Writing fundamental equations governing process Decide assumptions Identifying empirical correlations for process Model development Divide process into submodels Identify input / output parameters for sub-models Identification of design and operating variables Developing linkage between process parameters and energy consumption Experimentation Validation of model Refinement of model Target energy estimation Study of actual process operation (process audit) Operating procedure and practices Control strategy and instrumentation Process constraints Logbook parameters Data from industrial process Usage of model Parametric analysis Source: Vishal et al,

18 Target SEC (kj/kg) SEC (kj/kg ) Example: Glass Industry Furnace number Target SEC Actual SEC Target SEC estimated for 16 industrial furnaces Effect of furnace draw on target SEC is demonstrated Draw (TPD) Source: Vishal et al,

19 Source: Epstein et al,

20 20

21 Source: Epstein et al,

22 Conservation Supply Curves CSC for Electricity savings in EU, 2030 Source: Fleiter et al,

23 Cost of Saved Electricity (US2005 / kwh) Conservation supply curve for electricity savings in the Indian cement industry Automation 2. Additives 3. Optimization 4. Energy Efficient Lighting 5. Energy Efficient Motor 6. Sizing 7. Variable Spped Drives 8. New Equipment 9. Equipment Modificiation Retrofits 10. Waste Heat Recovery Source: Rane, 2009 Cumulative Electricity Savings (GWh) 23

24 Source: Ashby,

25 Source: Ashby

26 Source: Ashby

27 Summing up Non Ferrous Industry growth, energy intensive Scope for model based benchmarks Low SEC global competiveness, lower carbon footprint R&D for new processes, energy efficiency Conservation Supply Curves Demand Side Management Pilots for Renewable Energy use Dematerialisation, Eco-design 27

28 References (last accessed on Dec 3, 2012) Beck, T.R., Electrolytic Production of Aluminum, Electrochemistry Encyclopedia Electrochemical Technology Corp. ( Epstein M. et al, 2007: A 300 kw Solar Chemical Pilot Plant for the Carbothermic Production of Zinc, Journal of Solar Energy Engineering, Vol. 129, MAY Vishal, 2007: Sardeshpande, V., Gaitonde, U.N., Banerjee, R., Model based energy benchmarking for glass furnace, Energy Conversion and Management, (48)10, , June Rane, 2009: Rane, M., Chhabra, D., and Banerjee, R., Industrial DSM for Indian Power Sector. In Proceedings of International Conference on Energy and Environment (EnviroEnergy 2009, Taj Chandigarh, Chandigarh, India, March 19-21, Epstein M. et al, 2008: Towards the Industrial Solar Carbothermal Production of Zinc, Journal of Solar Energy Engineering, Vol. 130, February Tobias Fleiter et al, 2009: Costs and potentials of energy savings in European industry a critical assessment of the concept of conservation supply curves, ECEEE 2009 SUMMER STUDY, ACT! Innovate! Deliver! Reducing Energy Demand Sustainably. UNIDO, 2010: Global Industrial Energy Efficiency Benchmarking-An Energy Policy Tool, Working Paper, United Nations Industrial Development Organisation (UNIDO), November, ETP, 2008: Energy Technology Perspectives International Energy Agency (IEA), Paris, France. 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 Ashby 2009: Ashby MF. Materials and the environment: eco-informed material choice. Burlington,MA, USA: Butterworth- Heinemann; Ashby 2011: Ashby 2011 India Minerals and Metals Forum 2012, Ferrous and Non Ferrous, July 2012, (last accessed on Dec. 28 5, 2012)

29 End-note Source: Thank you 29