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ENERGY Conservation

Consultancy

By

Ravindra M Datar
Senergy Consultants (P) Ltd

www.senergy.co.in
senergy@vsnl.com
91-22-55993086
Why Conserve?
 Product need to be internationally competitive.
 Cost raises but selling price stagnates.
 Savings is surest way to increase profits.
 10-25% saving can be realized in many industries;
half of which with small investment.  
 The nation gains as
 A new captive power plant take 4 years to construct; while
benefits of savings can be enjoyed in 6 months.
 The power plant costs Rs 50,000/- per kW, while savings
costs are not even Rs 10,000/- per kW.
Senergy

Synergy
between
Our expertise on conservation of energy

&

Your experience & knowledge of


process, operations, plant engineering, etc.
To
Save Energy
Senergy is
• An ISO 9001-2000 company.
• In this field for more than 14 years.
• Team of experts headed by a technocrat
from IIT - Mumbai.
• A company with customer Base of 300
industries.
• Customer driven company with many repeat
orders & orders form group companies.
• Approved by MEDA & GEDA.
• Contributing Rs 50 crores/year, towards
conservation of energy.
Senergy

• Provides Personalised services.


• Conducts comprehensive & interactive
studies.
• Gives practical & realistic
recommendations.
• Provides services till actual realization of
saving.
• Can organize subsidies and soft loans.
• Take responsibility for turnkey
implementation, on specific requests.
Few of our clients

• Century Enka Ltd • Hindustan Lever Ltd


• Century Rayon • Nicolas Piramal India Ltd

• Nanavati Hospital • Wyeth Lederle Ltd


• Nirlon Ltd
• Essel World
• GTC Industries Ltd
• EBG India Pvt Ltd • Advani Oerlikon Ltd
• JBF Industries Ltd • Frigerio Conserva Allana Ltd
• Emco Ltd • Whirlpool of India Ltd
• PepsiCo India Ltd • Pidilite Industries Ltd

• ICI Ltd • Sumaira Group (Tanzania)


• Ceylon Glass Company Ltd
• Essel Propack Ltd
• MSEB
Senergy: Activities

• Energy Conservation Consultancy.

• Promotion of Renewable Energy Sources.

• Turnkey consultancy for non-standard suggestions.

• Consultancy for Process Audit & Yield Improvement.

• Consultancy for Proficient Plant Operations.


Road Map:
Energy Conservation
Consultancy
1. Team formation
2. Overview of Process & Operations
3. Analysis of Specific Energy Consumption
4. Energy Accounting & Balancing
5. Energy Consumers / Converters
6. Distribution Systems
7. Utilization systems
8. Identification of potential saving areas
9. Implementation
10.Monitoring
TEAM

• Participation of all concerned.


• Positive suggestions through various schemes.
• Immediate & correct evaluation of suggestions.
• Positive solutions for roadblocks / problem areas.
• Wider acceptance for recommendation.
• Quick and effective implementation.
• Development of knowledge bank.
• Continual improvements.
• Savings on sustainable basis.
Overview of Process /
Operations
• Brief description of activities, with
emphasis of major consumers.
• Process / Material flow diagram.
• Utilization pattern for major consumers.
• Co-relate the critical parameters at the
point of generation & utilization
– Air pressure at compressor outlet / point of
utilization
– Suction pressure of refrigeration compressor
/ process temperature
Specific Energy
Consumption
Specific energy is the energy consumed
per unit output.
Analyze variations with respect to
– Output
– Seasonal variations
– Yield

Start the analysis at Macro-level


then
Proceed towards Micro-level
Example
Specific Energy
34 Consumption Initial
Stage
Final
32
Ideal

30
Sp Energy (Rs/kg)

28

26

24

22

20
1000 1050 1100 1150 1200 1250 1300 1350 1400

Production (kg/day)
Energy Accounting /
Balance
Prepare break up of consumption for each
form of energy by
– Measuring energy consumption of individual
equipment.
– Noting down operating period.
– Take data from various sub-meters
Compare total consumption as estimated
above with actual consumption to ascertain
– “Unaccounted” or “Miscellaneous” portion of the
consumption
Analyze consumption pattern (wrt time)
Example
Energy Accounting / Balancing
Description % kWh/M
Illumination 30% 5,40,000
Air conditioning 20% 3,60,000
Computers 7.5% 1,35,000
Pumps 12.5% 2,25,000
Electrical Heating 2.5% 45,000
Residential & Commercial 15% 2,70,000
Miscellaneous 12.5% 2,25,000
Total 100% 18,00,000
Energy Accounting
Description Consumption
  kWh %
Residential & 270000 15.0%
Commercial
Hostels 420000 23.3%
Pumping 225000 12.5%
Common Lighting 120000 6.7%
Departments 765000 42.5%
Total 180000 100.0%
Average Power (kW)
Month Overall 22 to 6 6 to 9 & 9 to 12 18 to 22
12 to 18
Aug-04 2525 2096 2658 2979 2746
Sep-04 2545 2111 2687 2930 2807
Oct-04 2591 2177 2690 2962 2918
Nov-04 2390 2016 2472 2732 2700
Dec-04 2092 1706 2194 2500 2329
Jan-05 2204 1825 2287 2519 2539
Feb-05 2152 1772 2265 2479 2414
Mar-05 2693 2144 2851 3116 2950
Apr-05 2855 2416 3001 3308 3061
May-05 2704 2308 2843 3190 2821
Energy Consumers /
Converters
Evaluate performance of major consumers to
– Carry out energy balance for the entire system.
– Check if the equipment operates at design capacity.
– Estimate efficiency at design / operating capacity.
– Compute specific energy consumption.
– List the major losses and estimate their contribution.
– Discuss & finalize ways to eliminate / minimize the losses and optimize
the efficiency /output.
– Evaluate possibility of enhancing useful output.
– Check feasibility of using cheaper source of energy do the same work.
Basic Definitions

Efficiency:
Ratio of Energy utilized for useful work to the
total energy supplied to the equipment.
Ratio of to energy supplied less sum of all losses
to the total energy supplied to the equipment.
Capacity utilization:
Ratio of the Actual output to the Rated output of
the equipment.
Specific energy consumption:
Ratio of the total energy supplied to the
equipment to the Actual output.
Specific Power Consumption –
Shaft Power (kWh/TR)
Evaporator Condenser Temperature (OC)
Temp 20 25 30 35 40 45
(0C)

10 0.27 0.33 0.40 0.47 0.55 0.65


5 0.33 0.40 0.48 0.57 0.67 0.79
0 0.41 0.49 0.57 0.67 0.78 0.89
-5 0.50 0.59 0.69 0.80 0.91 1.04
-10 0.60 0.70 0.82 0.94 1.07 1.21
-15 0.73 0.84 0.97 1.10 1.25 1.42
-20 0.87 1.00 1.14 1.29 1.46 1.67
-25 1.04 1.18 1.33 1.51 1.72 1.96
-30 1.23 1.39 1.57 1.78 2.03 2.31
Refrigeration Effect (TR)
Evaporator Condenser Temperature (OC)
Temp 20 25 30 35 40 45
(0C)

10 100.0 96.8 93.7 90.5 87.3 83.9


5 83.1 80.4 77.7 74.8 71.9 68.9
0 68.4 66.1 63.6 61.1 58.4 55.7
-5 55.9 53.8 51.6 49.3 46.9 44.4
-10 45.0 43.1 41.1 39.1 36.9 34.9
-15 35.7 34.0 32.2 30.3 28.6 27.1
-20 27.8 26.2 24.6 23.1 21.8 20.7
-25 21.1 19.7 18.4 17.4 16.4 15.5
-30 15.5 14.4 13.5 12.7 12.0 11.4
Air Compressor
Pr Sp Power Sp Output Power

Bar kW/M3 M3/kW kW


1 0.037 27.0 100
2 0.057 17.6 153.3
3 0.077 13.0 207.3
4 0.086 11.7 231.6
7 0.108 9.3 291.6
10 0.128 7.8 345.6
15 0.154 6.5 416.9
Distribution Systems

• Utilities like steam are generated at centralized place &


distributed through out plant.
• Such distribution is always associated with drop in
energy level.
• Distribution losses are such losses expressed as fraction
(or percent) of the initial energy.
• Such losses can be in in more than one form like
pressure drop, heat gain, leakages, etc.
• Minimizing such losses is one of the simplest & surest
way of conservation of energy.
Example
Distribution Systems
Steam
• Insulation
• Leakages
• Pressure drop
– Routing
– Line size
• Trapping
– Location
– Size
– Type
Utilization Systems

• Efficient utilization of utilities / energy is of prime


importance.
• Conduct energy balance for each form of energy.
• Identify critical parameters for utilities.
• Validate criticality of process / plant parameters.
• Map process / plant requirement with generation for
critical parameters.
• Quantify waste streams and potential for energy
recovery through the same.
• Look for more economical source of energy.
Energy Recovery from Effluent Chilled
Water

Waste Ice 8.5 TPD Fresh Water 300C


221m3/day

Ch Water Process
110C

Plate Type
250C E T P
Effluent Heat
120C Exchanger

221m3/day

1250 TR / 221 M3/day


Chilled Water
System 130C
Identification
of

Energy Saving Areas


• Analyze the deviations from norms /
normal values.
• Identify reasons.
• Work out corrective action.
• Discuss with TEAM to formulate Action
Plan
• Make simple but complete fact sheet for
each area.
• Categorize areas based on ease of
implementation, investment, etc.
Implementation

• Pick up low hanging fruits – it goes in a great way


to boost up team moral and management support.
• Supervise actual implementation
• Provide assistance during commissioning &
trouble-shooting.
Monitoring

• Ensure that the Team is on the right path


and at correct pace.
• Measure the actual savings and ensure
realization on sustainable basis.
• Devise monitoring system for key energy
consumers & prepare log / data sheets.
• Install mechanism for suggestion scheme
with effective implementation.
• Monitor specific energy consumption at
macro as well as micro level.
In Nutshell
1. Team formation
2. Overview of Process & Operations
3. Analysis of Specific Energy Consumption
4. Energy Accounting & Balancing
5. Energy Consumers / Converters
6. Distribution Systems
7. Utilization systems
8. Identification of potential saving areas
9. Implementation
10.Monitoring
Thank

You!