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WELCOME. DATE : 25/11/04. Who Moved My Oil ?. EMERGENCE OF PCRA. SECTROAL APPROACH. COMMERCIAL. INDUSTRY. AGRICULTURE. PCRA. DOMESTIC. TRANSPORT. SCOPE OF ENERGY AUDIT. A GIST OF FIELD ACTIVITIES. INCREMENTAL SAVINGS - ALL SECTORS. VALUE (Rs.Crs.). 275. 220. QTY

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slide1
WELCOME

DATE : 25/11/04

sectroal approach
SECTROAL APPROACH

COMMERCIAL

INDUSTRY

AGRICULTURE

PCRA

DOMESTIC

TRANSPORT

slide7
INCREMENTAL SAVINGS - ALL SECTORS

VALUE

(Rs.Crs.)

275

220

QTY

(‘000 TONNES)

YEAR

slide8
RECURRING SAVINGS –

INDUSTRIAL SECTOR

952.23

Qty

(‘000 Tonnes)

701.00

VALUE

(Rs.Crs)

YEAR

slide9
PHILOSOPHY OF ENERGY AUDIT
  • Through energy audit, we optimize the consumption of fuel i.e. coal, electricity petroleum products etc.
  • To spread the benefits obtained through Energy Audit
  • in any one industry to entire cluster
  • To replicate the benefit obtained through Energy Audit in other industries through Education Campaign and ITPs
  • Sponsor R &D projects identified from Energy Audit.
slide11
MAJOR ENERGY AUDITS (Since 2001)

**P = Process; E=Engg; T=Textiles; G=Glass; M=Miscellaneous

*EYC indicates Estimate I Yearly Consumption of audited industrioes

slide12
MAJOR ENERGY AUDITS (Since 2001)

**P = Process; E=Engg; T=Textiles; G=Glass; M=Miscellaneous

*EYC indicates Estimate I Yearly Consumption of audited industrioes

slide13
Energy is Life

Conservation is instinct of life

GDP is inseparable from conservation /efficiency

Who are the Stake Holders?

slide14
ATMOSPHERE

ENVIRONMENT HYDROSPHERE

BIOSPHERE

FACTORY

PRODUCT MIX

LOGISTICS

PROCESS

MACHINERY

SCALE

QUALITY

SAFETY

STAFF

COMMUNITY

VENDORS

INPUTS

MARKETS

INDUSTRY ASSOCIATIONS

COMMERCE/BUSINESS/TRADE

IMPORTS / EXPORTS

ECONOMY/ FINANCE/ BANKING

TAXES / INCENTIVES

PROFITABILITY

CONSUMERS

GOVERNMENTS

POLICY

LAWS

REGULATORS

slide15
Energy is :
  • Food, Fodder , Fiber, Fuel
  • Health
  • Safety
  • Climate
  • Any greater cause than energy
  • conservation?
slide17
Energy is Consumed for emotional uplift like consumerism, competition, convenience, comfort, life style, luxury etc.
  • Energy & energy conservation is an issue of
  • Attitude
  • Values
  • Beliefs
  • Practices
slide18
Energy is an Emotion more than Knowledge
  • The T&D losses in Mumbai, Calcutta & Delhi are 10-11%, 18-19% & 30% respectively. In certain states it is 50%
  • Russia took 12 years to ratify Kyoto Protocol
  • USA is not convinced yet to ratify Kyoto Protocol
slide19
Energy & Resources
  • 50 years back we knew Drinking Water was free. Today it is NOT
  • Drinking water extraction in future may use oil drilling like technology and vast process plants to make the water potable.
  • Where is the energy for this future?
slide20
Energy & Resources
  • All of us believe today that Air is Free. Will it follow the route of Drinking Water in future?
  • For combustion and release of energy, air is as important as fuel if not more. How many of us measure and control the combustion process in totality ?.
slide21
Energy & Resources
  • How many of us check the air filter vis-à-vis the fuel tank level of our automobiles ?
  • Can you risk to Guess , billions of US dollars of packaged air in future and the life forms?
slide23
PCRA’s Mixed Experience
  • Enlightened industry is employing OEMs & Technology suppliers to do Energy Audit at regular intervals
  • MNCs are conducting Energy Audits of their vendor’s units over decades
  • Tea, Salt & Chemical Industry using water circulators or thermic fluid heaters to preheat air as a via media
pcra s mixed experience
PCRA’s Mixed Experience
  • Hotels are generating hot water from DG set hot flue gas. Hotels are using boilers to generate steam and run vapour absorption refrigeration systems
  • A very enlightened salt industry using vacuum flash for drying salt. Producing pure water & conserving ground water. A two in one salt manufacture cum desalination! Or is it Three in One?
pcra s mixed experience25
PCRA’s Mixed Experience
  • Some industries still are ignorant and secretive. Unwilling to allow the energy auditors to see the process, plant, quality control deptt etc. They still believeenergy conservation is on boiler floor and motor drives only
pcra s mixed experience26
PCRA’s Mixed Experience
  • The garbage collector’s van getting filled fastest. Sometimes some houses remain uncollected. The garbage collector wades through the traffic in search of easy / quick dumping grounds. Now the house holder is waiting in advance for the garbage collector to deposit / dispose off his consumption.
  • An increasing tendency of the industry to consume wood in boilers/ furnaces in place of oil/ coal
pcra s experience
PCRA’s Experience
  • PCRA does the scoping study, meeting & discussing with people, process study, equipment wise study, literature study etc before detailed energy audit. In a way we establish full communication by knowing the language of the industry.
  • In a textile spinning mill the exhaust fans were of overcapacity compared to inlet fans
slide29
PCRA’s Experience

Selection of suitable number of inlet fans, water spray pumps, exhaust fans along with relative humidity measurement saved 2.5 lacs KWh/Annum

slide30
PCRA’s Experience
  • Air compressor appears to follow 80:20 principle. It delivers only 20% effective output and wastes 80% of the input. Due to

- Deteriorated performance of internals

- Compressed air leaks

- Air pressure selection

- Single stage operation

slide31
PCRA’s Experience
  • - Inter stage coolers

- cooling Water Treatment

- Cooling Tower Performance

- Pressure drop

slide32
PCRA’s Experience

- In a dry cell manufacturing plant one of

the four compressors could be stopped

- 5% of the electricity generated in the country

runs air compressors

  • In a foundry the used sand of moulds is recycled after removal of organic binders and flux. The dryer used for this purpose was kept over fired to be on the safe side. An appreciation of quality measurement of fresh and recycled sands reduced the fuel consumption.
slide33
PCRA’s Experience
  • A steam less dairythat uses only hot water circulation. No boiler, no steam.This dairy does not have milk powder in the product mix
slide34
PCRA’s Experience
  • Optimizing refrigeration loads in a dairy.

20% of refrigeration loads were reduced by

- off peak operation of refrigeration for

ice build up in IBT

- Sequencing of IBT operation & avoid

unnecessary ice build up with respect

to stocks & expected inputs

slide35
PCRA’s Experience

- Control of ice build up to maximum 2 inch

- Automatic instrumentation for heating

and chilling to avoid over heating / fouling

& over chilling/ too low suction pressure.

-optimum insitu cleaning to improve

regeneration efficiency. Save

water/chemicals too

slide36
PCRA’s Experience

- Monitoring and adjusting cooling tower

for the rated range and approach. This

alone controls the Discharge Pressure of

the compressor

- Calculate regeneration efficiency in every

shift. Aim for 90%

slide37
PCRA’s Experience
  • In a Mirinda Orange Drink Plant found that it’s CO2 absorption requirement was half compared to exotic Coco-Cola. Higher temperature of chilling for the desi drinks are enough. Different energy settings for different product mix.
  • In a latex plant the OEM has set the chiller at +6 0 C of product temperature. The process needed higher temperature of 16 0 C! In operation, the product was shock chilled and allowed to thaw!! A good example of energy conservation at the interface of the equipment and process. The machine needs reset for a product outlet temp of 16 0 C.
slide38
PCRA’s Experience
  • An FMCG major was connected from an agricultural feeder. The voltage fluctuation causing recurrent disruptions. They were running DG sets at 20% load factor and disconnected the EB feeder. Suggested lock rotor protection/ re-acceleration after carrying equipment wise no load / part load/ full load readings. The EB feeder was revived. DG set shutdown.
slide39
PCRA’s Experience
  • In an asbestos plant, the asbestos, cement and fly ash slurry is processed in a vacuum drum filter for required thickness of sheets. The vacuum pump discharge temperature is 80 0 C. Suggested to utilize this waste heat to dry the sheets and reduce fuel firing and electricity

Amazing, is it not?

Lot of low lying fruits!

slide40
OPPORTUNINITES GALORE

TOP 10 PRIVATE COS ACCORDING TO POWER & FUEL COST(Rs. Crores)

Ref.Financial Express, Chennai 22.06.04

slide42
Concepts for Future
  • Individual Carbon Neutrality
  • Distributed Production for Distributed Consumption

Asymptote Nature?

Ecological Degradation

But ………

Production Engages

People + Locations

slide43
Concepts for Future
  • Food Miles
  • Up-gradation / harvesting of low grade energy sources (sun light, low temp.heat of flue gas from boiler, furnace, engines, low velocity wind by thermo compressors, heat pumps etc)
  • Awakening on common property rights of air, water, earth, sky….
slide44
Concepts for Future
  • Conflict resolution between interest holders of food, fibre, fodder, fuel
  • NPT on automobiles
  • Nuclear power for H2 production / desalination
  • Recycling industries for ferrous/ non-ferrous metals, plastics, paper etc.
slide45
Concepts for Future
  • Consumers shall pay for the cost of pollution (producer shall pay …..is past)
  • Press the Best Individuals, Institutions, Organizations, & Resources for energy conservation. e.g Brand Ambassadorsof the FMCG, Media, Chartered Accountants etc. This will ensure sustainable business as well as life
slide46
Concepts for Future
  • ICAI published a book on energy audit and management.
slide47
Concepts for Future
  • Enjoy the interest on the principal of nature’s bounty.Do not treat it as booty.Mankind should not be the worst NPA amongst the life forms.
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