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Resource Conservation at TTBG (Utilities). RESOURCES OF UTILITIES. Water. Resource. Fuel. Energy. Power. Summary of improvements in Utility. Power Conservation at TTBG (Utilities). Yearly KWH / MT Trend and 08-09 projection.

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Resource Conservation

at

TTBG (Utilities)


RESOURCES OF UTILITIES

Water

Resource

Fuel

Energy

Power



Power Conservation

at

TTBG (Utilities)


Yearly KWH / MT Trend and 08-09 projection

Projected KWH/MT is based on Apr -08 to Feb-09 Actual data

KWH/MT

There is continuous reduction in KWH/ MT except

in 05-06 as there was expansion of the plant




Power reduction in refrigeration system

2008-09

Power conservation in Refrigeration system

Increasing refrigeration efficiency

Reducing refrigeration requirement

Maximum TR generation through VAM

Increasing Efficiency of electrical chiller

Optimize department condition

Identify and stop conditioning of non critical area


Better

June end

Journey of continual power reduction in refrigeration system


Refrigeration Power consumption & Fresh air Enthalpy (Budget Vs Actual)

Actual power consumption is less due to lower enthalpy

  • Maximum benefit in power saving will be during monsoon period.

  • Expected Saving for the year of 2008-09 is 20 Lac KWh

Inspite of higher enthalpy ,the power cons is lesser .


Power conservation in other utility Areas Vs Actual)

Total Power saving achieved from above is at 1906kwh/day.


Fuel Conservation Vs Actual)

at

TTBG (Utilities)


Reduction in Fuel consumption Vs Actual)

2.5 KL/day saved due to TFH stoppage is included


Water Conservation Vs Actual)

at

TTBG (Utilities)



Way Vs Actual)forward

  • Possibility of further reduction in power consumption in compressed air system

  • Optimization of use of air conditioning equipments

  • Possibility to stop cooling water return pumps in spinning


THANKS Vs Actual)


Membrane Vs Actual)

Patented clip-in Joint

Collar to avoid fold of membrane

Diffused aeration system

2008-09

  • In fine bubble diffused aeration, compressed air is released through 0.6 mm holes in diffuser lines placed just above the bottom of aeration tank. The rising bubbles transfer oxygen to the water, as well as transport bottom water to the surface.

  • While in surface aeration, water is rotating with the help of mechanical agitators, during this operation, only the surface water comes in contact with atmospheric air and absorbs oxygen.

  • The efficiency of diffused aeration system is high ( 17 % at 3.5 height ) whereas efficiency of surface aerator is ( 5% at same height)

  • This will replace 22 kw x 2 nos. surface aerator with only one 22 kw blower .

  • Expected saving in kwh/day :550


Air Compressor – G Trend With and Without inverter Vs Actual)

Without Inverter

With Inverter

SAVINGS OF 23 KW/HOUR WITH INVERTER


Water conservation
Water Conservation Vs Actual)

Plate and tube type reverse osmosis plant installed for treatment of waste and

reutilized in process (Saving is approx 240 m3/day)


Problem faced during 2007~08 Vs Actual)

  • Low VAM output :-

  • Low Hot water temperature

  • Low chilled water pressure in poly while VAM is operated (without electrical chillers)

  • Low chilled water return temperature as load shared by electrical chiller machine .




Chilled water boosting pump Poly II VAM

Chilled water boosting pump Poly I

PHE of steam condensate at VAM

Return Chilled water line of Twisting air washer Plant-2 connected with VAM chilled water header



Journey of continual power reduction in refrigeration system improvement activity

Improvement in VAM

TR generation increased after implementation of improvement activities


Improvement in Electrical chillers improvement activity

Avg power cons per TR 0.73

(Area for improvement )

KWh/TR is high during Monsoon season due to high fresh air enthalpy




Cooling water distribution system chillers

UTILITY COOLING TOWER

PROCESS COOLING TOWER – 1ST

Nitrogen Plant

Air Comp. A

Air Comp. B

Air Comp. C

Air Comp. D

Air Comp. E

Air Comp. F

Air Comp. G

PROCESS COOLING TOWER – 2ND

Chiller - A

Chiller - B

Chiller - C

Chiller - D

Chiller - E

Chiller - F

Dryer - A

Dryer - B

Dryer - C

Dryer - D

Dryer - E

Poly-I

Poly-II


Cooling water distribution system after first modification chillers

Stand-by

UTILITY COOLING TOWER

PROCESS COOLING TOWER – 1ST

Close

Nitrogen Plant

Close

Close

Close

Air Comp. A

Air Comp. B

Air Comp. C

Air Comp. D

Air Comp. E

Air Comp. F

Air Comp. G

Close

Modification was carried out for utilizing only one process cooling tower for both poly process

PROCESS COOLING TOWER – 2ND

Modification

Chiller - A

Chiller - B

Chiller - C

Chiller - D

Chiller - E

Chiller - F

Dryer - A

Dryer - B

Dryer - C

Dryer - D

Dryer - E

Open

Open

Poly-I

Poly-II


Cooling water distribution system after second modification chillers

UTILITY COOLING TOWER

PROCESS COOLING TOWER – 1ST

Open

Nitrogen Plant

Close

Close

Open

Air Comp. A

Air Comp. B

Air Comp. C

Air Comp. D

Air Comp. E

Air Comp. F

Air Comp. G

Open

Open

Modification carried out in Feb’08 for utilising process cooling tower I for compressed air system and N2 system

PROCESS COOLING TOWER – 2ND

Close

Close

Modification

Closed

Chiller - A

Chiller - B

Chiller - C

Chiller - D

Chiller - E

Chiller - F

Dryer - A

Dryer - B

Dryer - C

Dryer - D

Dryer - E

Open

Open

Poly-I

Poly-II


Cooling water distribution system after third modification chillers

UTILITY COOLING TOWER

PROCESS COOLING TOWER – 1ST

Open

Nitrogen Plant

Close

Air Comp. A

Air Comp. B

Air Comp. C

Air Comp. D

Air Comp. E

Air Comp. F

Air Comp. G

Modification carried out In May’08 for Water and heat balance during operation of separate cooling tower for compressor & chiller

PROCESS COOLING TOWER – 2ND

Close

Close

Modification

Chiller - A

Chiller - B

Chiller - C

Chiller - D

Chiller - E

Chiller - F

Dryer - A

Dryer - B

Dryer - C

Dryer - D

Dryer - E

Open

Open

Poly-I

Poly-II


With above improvement cooling tower approach reduced from 5 to 3

Improvement in cooling tower approach after modifications in cooling water distribution system

UTILITY COOLING TOWER


Optimization of Utilities parameters to 3

* Microprocessor based control system installed at 2 chillers in place of electromechanical system

Remarks:

1) Process conditions are established through planned experimentation at processes.



Improvement in Electrical chiller to 3

Avg power cons per TR 0.73

(Area for improvement )

KWh/TR is high during Monsoon season due to high fresh air enthalpy


Power conservation in Air conditioning to 3

Close

Close

Before

After

2008-09

Modification in conditioned air distribution system of inverter room AHUs

BothAHU in operation

Only one AHU in operation


After to 3

Before

close

Power conservation in Boiler Area

2008-09

Modification in condensate transfer system

CV in line

Bothpumping station in line

Only one pumping station in line


2008-09 to 3

Schematic diagram of chilled water

  • Before expansion refrigeration load ~1600 TR (max. month avg.)

  • After expansion refrigeration load ~2800 TR ( max. month avg.)

  • VAM was installed and commissioned in 2006~07


Month-wise refrigeration requirement before & After of plant expansion

2008-09

  • Data of 2003~04 & 2006~07 is taken for comparison as during above years refrigeration system (consumption) was stable :-

  • Year 2004~05 and 2005~06: Plant was under commissioning

  • Year 2007~08 : Refrigeration load was manually reduced due to water crisis and problem in chillers


Saving :

Power saving ~ 28 KW / Hr

Power saving / annum ~ 2.5 lac Kwh

Verifying the results


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