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Energy Conservation
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  1. > Energy Conservation Issue: March 2010 EnMS Awareness Training Course

  2. The difference between what we do and what we are capable of doing would suffice to solve most of the world’s problem. - Mahatma Gandhi

  3. Energy Issue: July 2010 EnMS Awareness Training

  4. Issue: July 2010 EnMS Awareness Training

  5. Issue: July 2010 EnMS Awareness Training

  6. INDIAN ENERGY SCENARIO Issue: July 2010 EnMS Awareness Training

  7. Energy Intensity of India in the world Issue: July 2010 EnMS Awareness Training

  8. - India is rated as 4th largest producer of green house gas emmissions - Energy sector is the largest contributor of carbon dioxide emmissions - 55% of total emmissions in India comes from energy sector - includes emmissions from road transport, coal mining, fugitive emmissions from oil and natural gas, burning of traditional bio mass fules and emissions from industrial sector like cement etc - Energy efficiency measure to reduce GHG emmissions EFFECT ON GREEN HOUSE GAS EMMISSIONS Issue: July 2010 EnMS Awareness Training

  9. Key Greenhouse gases ( GHG ) driving Global warming • Carbon Dioxide – largely by fossils fuels • CFC’s – exist in very small –significant contributor to global warming • CH4 • PFC’s ( Perfluorocarbons) • SF6 – Sulfur hexafluoride • HFC’s – Hydro fluorocarbons EFFECT ON GREEN HOUSE GAS EMMISSIONS Issue: July 2010 EnMS Awareness Training

  10. SHARE OF GREENHOUSE GASES • Carbon Dioxide – 54% • CFC – 21% • Methane – 12% • Ozone – 7% • oxide – 6% EFFECT ON GREEN HOUSE GAS EMMISSIONS Issue: July 2010 EnMS Awareness Training

  11. Issue: March 2010 EnMS Awareness Training Course

  12. Power is a critical element for economic development and for improving the quality of life. • Annual Per capita consumption of India is among the lowest in the world. • People in a large number of villages have no access to electricity. • The end users of electricity like household, farmers, commercial establishments and industries are confronted with frequent power cuts, both scheduled and unscheduled causing great loss to the nation. POWER IS A CRITICAL ELEMENT Issue: July 2010 EnMS Awareness Training

  13. One of the reasons identified is “ in-efficient usage of Energy by Consumers. • Indian Government set up Bureau of Energy Efficiency (BEE) in the year 2002 with an objective of reducing “Energy Consumption” and promoting “Energy Conservation & Energy Efficiency” POWER IS A CRITICAL ELEMENT Issue: July 2010 EnMS Awareness Training

  14. The Bureau of Energy Efficiency (BEE) was established on 1st March 2002, under the Energy Conservation (EC) Act, 2001. • BEE is responsible for spearheading the improvement of energy efficiency in the economy through various regulatory and promotional instruments • Plan, manage and implement provisions the EC Act • Appliance standards and labeling • Industrial energy benchmarks • Energy Conservation Building Codes • Monitor energy use in high energy-consumption units • Certify and accredit energy auditors and energy managers BEE - Scope of Activities Issue: July 2010 EnMS Awareness Training

  15. Provide a policy framework and direction to national energy conservation activities • Disseminate information and knowledge, and facilitate pilot and demonstration projects • Establish EE delivery systems through Public-Private Partnerships (PPP). BEE - Scope of Activities Issue: July 2010 EnMS Awareness Training

  16. Notification of Designated Consumers Among 15 Energy Intensive Industries, 9 industries have been notified as Energy Intensive Industries as specified in the Schedule to the Energy Conservation Act, 2001 having annual energy consumption as indicated against each industry, as Designated consumers for the purposes of the EC Act:- Issue: July 2010 EnMS Awareness Training

  17. Issue: July 2010 EnMS Awareness Training

  18. Total Energy Consumption in MTOE Aluminum , 1.396 Cement, 14.47 Paper, 3.04 Chlor Alkali, 0.43 Fertilizer , 28.8 SpongeIron, 12.6 ThermalPower Integrated Steel Stations Plant, 35.5 151.7 The energy consumption share of each sector in MTOE is depicted in the chart below: Issue: July 2010 EnMS Awareness Training

  19. Iron & Steel 10% Fertilizers 15% Textile 25% Cement 15% (IEA estimates 18% CO2 emissions reduction by dissemination of BAT technologies) Pulp & Paper 25% Aluminium 10% Petrochemical 15% (IEA estimates 16% energy saving potential) Glass & Ceramics 20% Refineries 10% Total 20-30% Energy Saving Potential of Indian Industry Issue: July 2010 EnMS Awareness Training

  20. Efficient management of energy usage is one of the means of demonstrating good environmental stewardship. Efficient use of energy and its subsequent management presents a real test to many organisations. The ISO:50001-2011 standard assists organisations demonstrate efficient energy management. Certification to this new standard makes a statement about your organisation that will be understood by all stakeholders:  that you are demonstrating your commitment to improve energy performance Issue: July 2010 EnMS Awareness Training

  21. Energy Efficiency Benefits INDUSTRY • Reduced Energy Bills • Increased Competitiveness • Increased Productivity • Improved Quality • Increased Profits Issue: July 2010 EnMS Awareness Training

  22. Energy Efficiency Benefits NATION • Reduced Energy Imports • Avoided costs can be used for Poverty reduction • Conversion of Limited Resources • Improved Energy Security Issue: July 2010 EnMS Awareness Training

  23. Energy Efficiency Benefits GLOBE • Reduced GHG & other emissions • Maintains a sustainable environment Issue: July 2010 EnMS Awareness Training

  24. India’s Installed Power Capacity & Net Availability A considerable portion of the increase in electricity demand can be met by the following measures : Efficiency improvement Energy conservation Demand side management Issue: July 2010 EnMS Awareness Training

  25. STAR LABELING Issue: July 2010 EnMS Awareness Training

  26. EnMS Certification & EA Energy Management System Certification & Energy Audit Issue: July 2010 EnMS Awareness Training

  27. ENERGY AUDIT Energy Audit “An energy audit is an assessment and analysis of energy flows in a process or system, aimed at reducing the amount of energy input into the system without negatively affecting the output(s).” Objective The main objective of an energy audit is to explore various possibilities for energy conservation; Approach An energy audit requires a thorough and detailed study of every aspect of the system, through the performance of various tests and measurements. Issue: July 2010 EnMS Awareness Training

  28. EMS & EnMS EMS and EnMS complement each other as they share approximately 40%-45% of the same material concepts. These concepts include: scope; policy; identification of significant energy uses; legal and other requirements; objectives, targets and action plans, competency, training and awareness; communication; control of documents and records; operational control; monitoring and measurement; evaluation of compliance; corrective and preventive action; internal audits and management review. Where they differ is the EnMS’ requirement to measure, record, and improve energy performance, consumption and use over time Issue: July 2010 EnMS Awareness Training

  29. ISO:50001 & BS-EN 16001 1 Q: What are the benefits of ISO 50001:2011 Energy Management System (EnMS)? A: Benefits include: • Reduced overhead costs, thus increasing profitability • Enhanced competitiveness • Reducing fuel consumption • Increased awareness and assurance of legal, other and internal compliance requirements • Reduced emissions, such as Green House Gases, particulate matter, NOx and Sox • Increased efficiency of energy sources, equipment, processes and maintenance related energy uses activities Issue: July 2010 EnMS Awareness Training

  30. ISO:50001 & BS-EN 16001 3 Q: From a business perspective, what would be some key points of adopting ISO 50001? A: DOE studies indicate an average savings of 6.5% - 17%over 2 to 3 years, signifying a strong initial return on investment in an energy management system. Operationally, ISO50001 provides a formalized structure to ensure an organization’s objectives, targets and action plans related to energy use, consumption and performance improvements are met. Issue: July 2010 EnMS Awareness Training

  31. ISO:50001 & BS-EN 16001 ISO 50001 establishes a voluntary framework for any type of organization using energy- industry, buildings, and public sector. Potential impacts: Could influence up to 60% of the world’s energy use across many economic sectors Uptake of ISO 50001 will be driven by companies seeking an internationally recognized response to: •Energy cost reduction initiatives •Demand created along the manufacturing supply chain •Corporate sustainability programs •Increasing market value of “green manufacturing” / reduced carbon footprint. Future national carbon or energy taxes; •International climate agreements Issue: July 2010 EnMS Awareness Training

  32. ENERGY CONSERVATION IN STEEL FOUNDRIES Issue: July 2010 EnMS Awareness Training

  33. Flowchart for a typical foundry

  34. Summary of Operating tips in Induction melting furnace

  35. Energy saving in the machine shop For efficient operation, carry out routine and simple maintenance of machine tools .this will help avoid expensive breakdown maintenance, which also leads to loss of production and other associated losses. Such routine maintenance takes only a few minutes to complete and should be conducted before the shift begins. the routine maintenance of machine tools: • Clean chips from the chip pan. • Check hydraulic oil level in the main hydraulic tank and top up if required . • Check the coolant levels in the coolant sump and top up, if required .

  36. Energy saving in the machine shop

  37. Energy Savings in the Compressed Air System • Air compressors are used in the machine shop for pneumatic equipment and machine tools. Air compression consumes a lot of energy. From figure it is clear that only 10-30% of input energy to the compressor reaches the point of end –use and the balance 90-70% of the input energy is wasted in the form of friction and heat loss.

  38. Energy Savings in the Compressed Air System

  39. Summary of operating tips in core-making and heat treatment furnaces

  40. Energy Savings in the Compressed Air System

  41. Energy Efficiency IS THE KEY TO SURVIVAL

  42. Benefits of using properly sized motors

  43. Energy conservation potential in different sections of a foundry

  44. Methodology for energy conservation

  45. Power distribution tree

  46. Cycle time of Individual activities during Melting Operation Reduce all these activities

  47. Issue: July 2010 EnMS Awareness Training