MISCELLANEOUS ENERGY

SAVING IDEAS / CASE

STUDIES

Confederation of Indian Industry

CII – Godrej Green Business Centre, Hyderabad, India
 Solar Mill
❖The Solar Mill Generates
 Energy during day and night time
 Standing at about 1 meter height, Solar Mill
meets building code requirements.
 3 Vertical-Axis Wind Turbines coupled to 3
permanent magnet generators
 On-Board “Smart” Electronics include dynamic
Maximum Power Point Tracking (MPPT) and
connectivity
 Cut-in wind speed – 2 m/s & Cut-out wind
speed – 18 m/s.

© Confederation of Indian Industry

Solar Mill

13kW- Residence, 10kW- Sidvin Plastech,

Shamshabad Shameerpet

5kW- GreenAssets,
5kW- Dexler, Bangalore
Dehradun

© Confederation of Indian Industry

Higher Efficiency Bifacial Solar panels

4 © Confederation of Indian Industry

 Higher Efficiency Bifacial Solar panels

 Bifacial modules offers big potential for increasing

yield
 Demonstration shows bifacial gains of 15% - 25%
❖ With larger commercial systems, realistic bifacial gains are
expected in a range from 5% to 15%
 Optimization of mounting geometry and mounting
structure is essential in order to draw the full benefits
from bifacial PV modules
 Developed in Sweden by PPAM Solkraft AB

© Confederation of Indian Industry

Higher Efficiency Bifacial Solar panels

6 © Confederation of Indian Industry

Higher Efficiency Bifacial Solar panels

 Comparison of bifacial solar panels with

conventional panels
❖ 3.7% more efficient
❖ Realistic gain

5% to 15%

 160kWp to be installed in CII Green Business

Centre, Hyderabad

© Confederation of Indian Industry

Higher Efficiency Bifacial Solar panels

 Enhanced electrical properties of

bifacial panels
20 % Bifacial
Model PPAM-Transparium
Effect
Max. Power [Pmax] 360Wp 432Wp

Open circuit Voltage [Voc] 52,1V 52,1V

Max. Pow. Voltage[Vmpp] 41,9 V 41,9 V

Power Tolerance -3%/+5 % -3/+5 %

Module Efficiency 18.6% 22.3 %

© Confederation of Indian Industry

9 © Confederation of Indian Industry
10 © Confederation of Indian Industry
Low Grade Heat Recovery from utilities

11 © Confederation of Indian Industry

 www.akxatech.com
contact@akxatech.com
+91-9243209569

Harnessing Data , Creating Value

“OPTIMakx-PID”
Fluctuation Assessment/Diagnosis& Control System
Optimisation Tool
For Productivity/Energy Efficiency Enhancement

BALCO

© Confederation of Indian Industry

 Process Plant Fluctuations :: Sources

(Process Control) (Automation)

Controller related Issues Cascade Loops
(settings, error band, OP limits) (series action, master
slave mismatch)

(Mechanical)
(E & I)
Valve/Damper/Feeder
Transmitter/Sensor
Operation
Issues
(sticky valves, choking,
(spikes, drifts, resolution)
nonlinear flows)

(Process/QA) (Projects)
External Disturbances Design Limitations
(Sampling method, uncontrollable (pumps, valve, VFD
raw material quality or variability capacities)
from upstream operations)
© Confederation of Indian Industry
 Assessment of Furnace Temperature PIDs..

Section/ PV SP Controller OP MV
Status
Zone/ variability variability Error % Variability Variability

1 Good 9.39 9.33 0.00022 29.24 25.47

2 Average 9.14 9.14 0.009 45.78 42.52
3 Average 8.87 9.1 0.0018 45.85 41.99
4 Low 14.19 5.22 0.0282 78.49 73.98
5 Average 9.11 9.14 0.0035 50.98 46.61
6 Good 9.09 9.13 0.0001 35.57 34.71
7 Average 9.09 9.17 0.0014 42.01 40
8 Low 17.72 9.56 0.0297 86.88 71.94
9 Good 9.44 9.39 0.00018 34.12 30.96

© Confederation of Indian Industry

 Terminology and Notes…

• PV = Actual Temperature, SP = Set Point

• OP = Injector Pulse Rate, MV = Injectors %.
• Non Healthy Data (PV/SP values -999) removed.
• Variability = std. dev/average * 100
• % Error = abs(PV-SP)/SP*100 for each data point
• Controller Error = Average of Error over sample set.
Notes: Assessment is based on the 5 minutes sampling data. Hence may be very coarse and preliminary.
Higher resolution data (15 seconds or lower sampling time) can give better assessment and more
accurate diagnosis.
For Example: Controller Errors are smaller (because in 5 minutes sample time PID is able to bring PV to
SP). This error will be realistic (and will be higher may be in the ragne of 1% or so) if dynamics are
captured with 10 second data.
© Confederation of Indian Industry
 Overall Observations..

• Controller Error is <0.1% for all controllers. From normal Temperature controller norms –
it is “GOOD” performance especially for servo control problem where Set Point is
changing.
• In present case < 0.001% error is taken as good. But needs more investigation with fine
sampling interval data.
• Large fluctuations > 25% in Injector pulse rate indicate issues with controller output
response. Especially zones 4, 8 and 9 have higher fluctuations. This surely has scope for
more investigation.
• Higher variability in controller OP is a sign of aggressively tuned controller.
• OP reversal index (sudden changes in reverse direction in two consecutive signals) is also
high for some of the controllers. This also could be due few choked or suboptimially
working injectors. Needs investigation.
• Definite scope for working on this and reducing overall fuel consumption to achieve the
same controller performance., © Confederation of Indian Industry
 other areas where OPTIMakx can contribute..

• Overall assessment of variation in Injector Load

• Detailed assessment of Temperature Cycle (with refined data)
• Cascade Control (Master controller) design for fine tuning of overall furnace
performance (upto 3% lower energy consumption possible if we design a single master controller)
• Complete health check up of all the Flow and Pressure control Valves/Injectors
for Stiction, Malfunction and Response (this will help in taking directed repairs --- preventive
maintenance).

• Performance assessment of PID settings (in the Panels) for all the VFD in the
plants for optimum response of speed control (3 to 5% reduction in power consumption
for drives from present level)

• Ball Mill Section (if they have carbon paste – electrde preparation section) : we
can analyze Mill Grindability, Feed controllers, quality fluctuations and mixing
consistencies in mixers.
© Confederation of Indian Industry
Optimizing PID Loop of the Bake Oven Furnce

❖ Benefits:
 Saving potential:
 Savings are estimated considering 2% reduction in
fuel consumption
 This can be implemented for Bake Oven 1 & 2, can
be implemented for Bake Oven 3 & 4 in a phased
manner.

Annual savings - Rs. 64.00 Lakhs

Investment - Rs. 8.00 Lakhs
Payback period - 2 months
© Confederation of Indian Industry
 BLDC MOTORS
❖ A brushless DC (BLDC) motor is a
synchronous electric Motor
 powered by direct-current (DC)
electricity
 brush-system/commutator assembly is
replaced by an electronic controller
 electronic controller can use position
information of the rotor, plus the
desired direction for the motor

❖ In BLDC motors, current to torque

and voltage to rpm are linear

© Confederation of Indian Industry
BLDC MOTORS - WORKING

20 © Confederation of Indian Industry

Comparison DC Vs BLDC

© Confederation of Indian Industry

Lobe Type Blowers Vs Screw Blowers

22 © Confederation of Indian Industry

Lobe Type Blowers Vs Screw Blowers

23 © Confederation of Indian Industry

Lobe Type Blowers Vs Screw Blowers

24 © Confederation of Indian Industry

HOC Dryers

25 © Confederation of Indian Industry

 Replace single phase ESP transformers with 3-phase transformers

❖ Pollution norms have become strict to

reduce the emissions less than 30
mg/Nm3.
❖ Installation of a 3-phase transformer
with better dust collection efficiency
reduces the emission levels in addition
to reduction in power consumption
❖ Higher average DC voltage due to lower
ripples resulting in higher corona current
and better dust collection
 Lower ripple also reduc-es harmonic
current and cable heating – increases
cable life
© Confederation of Indian Industry
Replace single phase ESP transformers with 3-phase transformers

© Confederation of Indian Industry

Light Pipe

© Confederation of Indian Industry

Light Pipe

© Confederation of Indian Industry

Automatic Tube Cleaning System

30 © Confederation of Indian Industry

 Observations – Automatic Tube Cleaning System

❖ Pros
 Maintains the cleanliness
of condenser tubes Before

 Lowers the frequency of

condenser cleaning
❖ Cons
 Costly Technology After

31 © Confederation of Indian Industry

Automatic Tube Cleaning System

32 © Confederation of Indian Industry

ECOMESH – Evaporative cooling to improve condenser performance

33 © Confederation of Indian Industry

 Heat Recovery From Rotary Kiln

❖ Kiln surface temperature varies

from 200 deg C to 300 deg C
❖ Radiant recovery panels recover
heat from high temperature kiln
surface
❖ Heat recovered is transferred to
fluid in flowing in Cu pipes
 Can be used for feed water heating

34 © Confederation of Indian Industry

Heat Recovery From Rotary Kiln

35 © Confederation of Indian Industry

Install IFC (Intelligent flow controller)

❖ Demand side control system

❖ Reduces the artificial demand
due to fluctuations at the
demand side (Pressure)
❖ Controls the CFM based on the
feed back i.e. pressure at
demand side
❖ Create the Buffer which will
meet the artificial demand
❖ Maintains the constant
pressure
© Confederation of Indian Industry
Install IFC (Intelligent flow controller)

© Confederation of Indian Industry

Install IFC (Intelligent flow controller)

© Confederation of Indian Industry

Aluminum Piping for Compressed Air Network
M.S. Pipe gets
thick and rough by
getting oxidized
with particles.
Oil, water, leading to
Decrease in air
quality and
higher energy
consumption
Aluminium eliminates
risk
of pollution as time
goes
© Confederation of Indian Industry
Aluminum Piping for Compressed Air Network

© Confederation of Indian Industry

Comparison: Diameters and weight of MS Pipe and Aluminium
Pipe with comparable flow

Steel Pipe Dia. 48.3mmx6m Aluminium Pipe Dia. 40mmx6m

length=19.5 kg length=4 kg
Steel Pipe Dia. 76.1mmx6m Aluminium Pipe Dia. 63mmx6m
length=34.5 kg length=6.4 kg
Steel Pipe Dia. 88.9mmx6m Aluminium Pipe Dia.
length=40.5 kg 76.1mmx6m length=9.4 kg

© Confederation of Indian Industry

 Micro-turbine
Boiler ❖ 1.8 TPH steam at 65 kg/cm2
19 TPH @ 65 kg/cm2 & 465 reduced to 3.6 kg/cm2 in
Deg C
PRDS II
17.2 TPH ❖ Micro turbine installed to

1.8 TPH
make use of the steam
Back pressure
Turbine available
 Design for 67 kg/cm2 to 4.5
HP Steam 1.2 TPH @ 11 kg/cm2
kg/cm2
PRDS-I
 100-150 kW produced
LP Steam to Process  Supplement non critical
PRDS-II
16 TPH @ 4.5 kg/cm2
load
HP Steam to Process
42 © Confederation of Indian Industry
 Micro-turbine
Boiler

19 TPH @ 65 kg/cm2 & 465 Deg C

1.8 TPH
17.2 TPH

Micro
Turbine Back pressure Savings-Rs. 42.00 Lakhs
Turbine

Exhaust Steam 1.8 TPH @ 4.5 kg/cm2

Investment-Rs. 40.00 Lakhs
300 Deg C
Payback-12 Months
HP Steam 1.2 TPH @ 11 kg/cm2
PRDS-I

LP Steam to Process
HP Steam to Process

43 © Confederation of Indian Industry

Data Analytics

❖ Data Analytics is one of the other fields which has a huge potential to not only
improve the plant performance but also to improve the overall reliability of
the plant
❖ It can be used in various areas for Thermal Power Plants like
 Predictive Analysis
 Spares management

 Better monitoring of efficiency parameters

 Preparation of operational benchmarks

 Study of variations

 Supply side – fuel

 Operational variation – performance parameters
 Demand side variations – frequency, load demands
© Confederation of Indian Industry
 Data Analytics

❖ Case Study – Using Data Analytics to analyse

reasons for high vibrations
 High Vibrations with an increasing trend
for turbine rear and front
 After analysis of more than 600 process Vibration Trend
parameters
 Analysis done for a period of more than 2
months
 More than 80, 000 event alerts analysed

 Results
 Control Oil header pressure increased from
8.4 to 9.0 Kg/cm2
Drop in vibration with changes to
 Drop in main oil temperature by 3-4 Deg C
© Confederation of Indian Industry the parameters
Thank You….

Contact:
Mehul Tatia
Counsellor
Confederation of Indian Industry
CII – Godrej Green Business Centre
Survey # 64, Kothaguda Post
R R District, Hyderabad 500081 INDIA

Direct: +91 9849909666

Email: mehul.tatia@cii.in
Web: www.greenbusinesscentre.com / www.cii.in

46 © Confederation of Indian Industry