Energy Efficiency-From a Process Perspective

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Energy Efficiency-from aprocess perspective

Presentation at BEE Workshop for Textilesector at Madurai on 20th November 2010

By S Kannan, Certified Energy Auditor

Director -AMSET Energy Systems andSolutions Private Limited, Trichy


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Presentation structure

EnergyLaws/Basics

Energy costs/prices

Energy-Process

Energy in Textile sector

Energy Audits

Future Energy

About AMSET

Back to Basics


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Energy Law/Basics

I Law- Law of ConservationEnergy can be neither created nor destroyed. It can be

transformed from one form into another form. Totalquantityof energy in the universe remains constant

II Law (Entropy-Law of degradation)Thequalityof this energy is degraded irreversiblyEntropy is a measure of disorder or uncertainty about a

system

Sum total of Energy in the universe is constant, ever was,always will be, moving into form, through form and out ofform.


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Basic definitions

Energy conservation: Reduction of Energyconsumption in physical terms

Energy efficiency: Reduction of Energy intensityin a specific product, process, area of productionor consumption, without affecting output,consumption or comfort levels

Energy efficiency contributes to Energyconservation


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Energy costs-India

Type Installationcost-RsCrore/MW

Generationcost-Rs/kw.hr

Thermal 3.5 to 4.0 1.2 to 2.5

Hydel 1.8 to 2.5 0.5-1.0

Wind 5.0 to 6.0 2.8 to 3.8

Solar 22.0 to 30.0 14.0 to 18.0


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Energy prices- India

Agriculturefree

Domestic-homes- Rs 1.00 to Rs 2.00/kw.hr

Industries- Rs 3.00 to Rs 6.00/kw.hr

Commercial sector- Rs 5.00 to Rs 7.00/kw.hr

Cost of Diesel generation-3 to 3.5 units/lit=Rs 13-15/kw.hr

Aggregate Technical & Commercial [AT & C] losses is between 15% to50% varying across states of India.


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Process

Input Process Output

Production is a process

Material Management is a process

Marketing is a process

Ultimately Business is a process!!

But the ENERGY process of any BusinessIMPACTS other key Performance indicators

of Business


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Energyprocess parameter

Y = f(X)Output (Product/Services)= f (M,P,E,..)M- Material (Material cost)

P-People (Wages)E-Energy (Bill-Fuel + Power)

Efficiency= Output/Input

A Mass balance & Energy balance performed onprocesses, will establish the relationshipbetween the above key variables


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Process or UnitOperation

Gaseous Emission

Product

By Product

Wastewater

Liquid waste forstorage and disposal

Solid wastefor storageand disposal

Raw

materials

Chemicals

Water/Air

Energy/power

Recycle

Reusable wastein other

operation

Components of material balanceComponents of Mass Balance

Raw

Materials

Chemicals

Water/Air

Energy/Power

Recycle

ReusableWaste in

Other operation

GaseousEmission

Product

By product

Liquid wasteFor storage

And disposalSolid waste

For storage anddisposal

Waste water


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Process or UnitOperation

Energy in Vapours

Radiation loss

Energy in hot

poducts

Energy in hotResidues

Energy in condensate

Energy incooling water

Electricity

Steam

Cooling

Water

Chilled Water

Compressed Air

Energy in RawMaterial

Components of Energy BalanceComponents of Energy Balance

Electricity

Steam

Cooling

Water

Chilled water

CompressedAir

Energy in Rawmaterial

Energy invapours

Radiation loss

Energy in hot

ProductsEnergy in hot

residue

Energy inCondensate

Energy inCooling water


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PDCA in Energy Management

PDCA-Plan, Do , Check & ActOriginally it was PDSA, the S denoting Study, which was

replaced with C for Check.The Plan & Check fit into theories while Do & Act fit into

application rendering a balanced approach.PDCA is simple and effective, but need to be practicedmeticulously on all processes which add value tobusiness.

Energy being a major cost parameter in Business, is a

good candidate for practicing PDCA

Energy saved= Earned profits


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SPECIFIC

OUTPU

T

BC- WASTAGE

EFFORT

ECO

ECO- ENERGY CONSERVATION OPPERTUNITY

A B C

AB- SPECIFIC CONSUMPTION OF

PRESENT SYSTEM

AC-ACTUAL ENERGY INPUT

D

AD- SPECIFIC CONSUMPTION


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Input RawMaterials

IntermediatesPROCESS PROCESS PROCESS

EnvironmentalAspects

Environmental

(Env Effects)

StakeholdersGovernment

Hazards

Working

Conditions

Employees

ENERGY

Analysis ForEnergy

Conservationopportunities

PROFIT PLANET PEOPLE = ENERGY RHYTHM

OUTPUT

PRODUCTS

QUALITY

CHARACTERISTICS

PRODUCT QUALITY

CUSTOMER

CRITICAL ASPECTS OF QUALITY,ENVT,OHS &EC

INTEGRATED MANAGEMENT


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Textile Sector-Overview

Textile Industry- Identified as Energy Intensiveindustry under Energy Conservation act 2001- >3000 MTOE/annum

Energy Intensity-10.4% of Total Industrial

Energy consumption 12-15% of manufacturing cost is Energy-

comprising Thermal & Electrical energy Energy saving potential > 15% > 600 MW

More than 60% of Designated consumers inTamilnadu are Textile units [> 3000MTOE/annum


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Electricity Consumption in aComposite Mill

Lighting

4%

Others

8%

Wet Process

10%

Humidi-

fication

19%Weaving

13%

WeavingPreparatory

5%

Ring Frame

28%

Spinning

Preparatory

13%


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Heat Energy Consumption in aComposite Mill

Steam

Distribution

Network

10%

Boiler Plant

25%

Humidi-

fication &Others

15%

Dyeing &printing

15%

Bleaching &

Finishing

35%


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Specific Electricity Consumption inTextile Mills

Mill Type & Range Kwh/ KgSpinning Mills

Maximum 6.60

Minimum 2.58Average 4.63

Composite Mills

Maximum 19.50Minimum 6.70

Average 13.10


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Energy saving measures in textileIndustries

Installing high efficiency Atomizer in lieu of Nozzles inhumidification plants, which result in substantial energysavings

Installing energy efficient fans/Blowers in Ring frames, by

which a 20% reduction in Power consumption is achieved. Installing VFD for Humidification fans , which will result in

annual saving in the tune of 25-30%

Convert V-belt drives to synthetic flat belt drives for the TFOmachines, as result of this, the annual saving will be 4% permachine.

Installing VFD for Autocore suction motor. By this, 15-20 %energy can be saved.

Preheating of Boiler feed water by Solar Thermal, resulting in

Fuel savings Contd..


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Energy saving measures in textileIndustries-contd..

Installing VFD for water circulating pumps of jet dyeingmachine, which will result in 35 % energy saving.

Reducing the speed of Exhaust fans in stenters by usingVFD, by which a 40% savings can be achieved

GENERAL Measures

Replacing old motors with Energy efficient motors

Avoiding idle operation of motors

Installing waste heat recovery systems, wherever possible. Reducing Transformer & Cabling losses

Phasing out of old lights and switch over to Energy

Efficient lights

Energy conservation in office/administrative buildings-


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Energy Audits..

As per Energy Conservation act 2001,Energy Audit is defined as theverification, monitoring and analysis of use

of Energy including submission ofTechnical report containing

recommendations for improving Energy

efficiency withcost benefitanalysis andaction plantoreduce Energyconsumption.


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Energy use-Areas

Thermal Energy systems

Boilers, Steam systems, Furnaces, HeatExchangers, Insulation and Refractory,

Co-generation, Waste Heat Recovery

Electrical Energy systems

Motors, Pumps, Compressors, HVAC, Fans& Blowers, DG system, Lighting,Transformer, Cabling


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Efficiency options

Reduction of Specific Energy Consumption per unit ofProduction/Service

Loss minimization

Waste Minimization

Low cost Energy substitution Renewable application

Process savings- Raw Material & Wages reduction

Investment in Energy efficiency is estimated around Rs 1

cr/MW while for a Power producing plant in > Rs 4Crores/MW + Generation cost!!

1 kwh saved mitigates 1 kg of Co2.


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Approach to Energy Audit

Energy Audit scope-typicalEnergy Audit-Scope.doc

Energy Data questionnaire-Thermal

Energy Data questionnaire-ElectricalEnergy_Audit-Data sheet.doc

Target Energy

I t t Li t f E A dit T i l
http://localhost/var/www/apps/conversion/tmp/scratch_1/Energy%20Audit-Scope.dochttp://localhost/var/www/apps/conversion/tmp/scratch_1/Energy%20Audit-Scope.dochttp://localhost/var/www/apps/conversion/tmp/scratch_1/Energy_Audit-Data%20sheet.dochttp://localhost/var/www/apps/conversion/tmp/scratch_1/Energy_Audit-Data%20sheet.dochttp://localhost/var/www/apps/conversion/tmp/scratch_1/Energy_Audit-Data%20sheet.dochttp://localhost/var/www/apps/conversion/tmp/scratch_1/Energy_Audit-Data%20sheet.dochttp://localhost/var/www/apps/conversion/tmp/scratch_1/Energy%20Audit-Scope.dochttp://localhost/var/www/apps/conversion/tmp/scratch_1/Energy%20Audit-Scope.dochttp://localhost/var/www/apps/conversion/tmp/scratch_1/Energy%20Audit-Scope.doc


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Instrument List for Energy Audit-Typical

THERMAL

No.

Instrument Intended Use

1Flue Gas

Analysers

Used for optimizing the combustion efficiency by measuring/monitoringthe oxygen and CO levels in flue gas of boilers, furnaces etc. and

calculation of CO2 percentage in excess air level and efficiency.

2Temperature

IndicatorsUsed for measuring temperatures of gases/air, iquids, slurries, semi

solids, powders etc. Using different types of probes.

3Infrared

ThermometersUsed for measuring temperatures from a distance using infrared

technology.

4Thermal

Insulation scanner

Used for measuring loss of energy in Kcal per unit area from hot/coldinsulated surfaces. The total loss can be obtained by multiplying the

total surface under study.

5Steam Trap

MonitorUsed for performance evaluation of steam Traps.

6Conductivity

MeterUsed for on the spot water analysis of the amount of dissolved solids in

water.

7 pH meterUsed for on the spot analysis of effective acidity or alkalinity of a

solution/water. Acidity /alkalinity water.

8Thermo-

hygrometer

Used for measurement of air velocity & humidification, ventilation, Air-

conditioning and refrigeration systems etc.

9Ultrasonic Flow

MeterUsed for measurement of flow of liquids through pipelines of various sizes

through ultrasonic sensors mounted on the pipelines.

10U-Tube

ManometerUsed for measurement of differential pressure.

11 Digital Manometer Used for measurement of differential pressure.

12 Visguage Used for measurement of differential viscosity.

13 Used Lube OilTest Kit

Used for testing lube oil.


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ELECTRICAL

1Non-ContactTachometer

Used for measurement of speed of rotation equipment.

2 Demand Analyser Used for measurement and analysis of electrical load and demand control.

3 Power Analyser Used for measurement and analysis of electrical Power.

4 Harmonic Analyser Used for analysis of harmonics in power System.

5 Luxmeter Used for measurement of illumination level.

6 Clip on Dig. WattMeter

Used for measurement of power without interrupting the connections.

7 Clip on Dig. PF Meter Used for measurement of power factor without interrupting the connection.

8 Clamp on amp. Meter Used for measurement of current without Interrupting the connections.

9 Digital Multimeter Used for measurement of voltage. Current and resistance.

10 Frequency Meter Used for measurement of power supply frequency.

11 Earth Leakage Tester Used for the leakage current in the earthing.


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Future Energy

The best is the enemy of the

good


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Reserves Background-Oil/Gas

Oil/Gas- With all information pollution from media aboutexhaustion, the fact remains that the exact amount ofoil/gas reserves is not explored/published!!

Opinion of world running out of oil range from year Year2030 to 2083 to 2100. We may NOT be alive beyond

Year 2100 to verify this !! Cost of oil drilling is around $ 15/barrel, while the price is

quoting around $ 80/barrel. Even at $ 80/barrel [=165 litres], adding the cost of

refining, the cost of oil [petrol/diesel] works out to Rs

25/litre, while it is being sold at > Rs 45/litreaverage.Almost Govt. receives > Rs 20/litre of oil sold,by means of Taxes and Duties.


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Reserves Background-Coal

Under current Reserve to Production ratio, India Coal reserves areestimated to last > 200 years.

Many areas in the states of Chattisgarh/MP/Bihar/Jharkhand/Orissawhich have Coal reserves, are in areas reserved as forests. Miningcoal from forest will call for felling of trees, which will impact themonsoon rains, again a key factor affecting the livelihood of Indian

population. Also the quality of Indian Coal is poor compared to that of

Australia/Indonesia, containing around 40% ash, which does notgive energy and have disposal problems.

Coal based power plants pollutes the environment and a recentstudy of IIM-A has estimated the health cost as Rs 3/kw.hr, which

is more than generation cost!! Most polluted city of India is NOT Delhi or Mumbai or Bangalore or

Chennai. It is Raipur in Chattisgarh, owing to large scale Coalmining!!.


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EnergyFuture trends-Supply side

Share of Renewable will increase in the Energymix.

Generation cost of Solar is expected to comedown drastically by/before Circa 2015.

More mini Hydel plants will get installed.

Rural energy-Micro turbines/Biomass

Share of Gas will increase, as many gas finds

are reported-Reliance/Cairn.. Reduction in AT & C losses. Many Electricity

boards are mandated.


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Energy-Future trends-Demand side

As happened in Telecom, consumers willhave the option to chose their Energy

supplier.

Energy pricing will be aggressive like pre-paid, post-paid, off-peak etc.

Off-grid consumers-islanding Energy

Off shore energy-wind/geothermal


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AMSET Energy Systems &Solutions Private Limited,Trichy

-team of Energy

Auditors/Managers certified byBureau of Energy Efficiency


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AMSET Energy

Agriculture

Manufacturing Existing Economy

Services

Experiential Future contributors

Transformational

Energy is used everywhereE=mc2


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AMSET Energy- vision

Enable Businesses to reduce Energy

costs, by involving People, contributing to

Profits and better Planet


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Rangeof Services

AMSET offers the following services

Awareness program on Energy costs-conservation-efficiency Energy Audits-Preliminary [walk-through] and Investment grade Carbon advisory-foot printing Energy Management- from a Cost management perspective Total Cost Management-Process approach-Energy + Material +

Wages- Cost of Energy related to other major costs. Future Energy- evolution of new Energy technologies Excellence in Energy Management-a journey comprising above


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The product of a

Consultant should beresults for clients-NOT

reports


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Return to Energy Basics

Energy law-I

Energy can be neither created nordestroyed. It can be transformed from oneform into another form.Total quantityofenergy in the universe remains constant

But.


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Law II

Thequalityof this energy is degradedirreversiblyEntropy is a measure of disorder or

uncertainty about a system

Organizations to evolve a robust Energy

Management system, with policies andPlanning.Energy can be planned and controlled..


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Sum total of Energy in theuniverse is constant, ever was,always will be, moving intoform, through form and out ofform.

But It comes with a COST


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Input RawMaterials

IntermediatesPROCESS PROCESS PROCESS

EnvironmentalAspects

Environmental

(Env Effects)

StakeholdersGovernment

Hazards

WorkingConditions

Employees

ENERGY

Analysis ForEnergy

Conservationopportunities

PROFIT PLANET PEOPLE = ENERGY RHYTHM

OUTPUT

PRODUCTS

QUALITY

CHARACTERISTICS

PRODUCT QUALITY

CUSTOMER

CRITICAL ASPECTS OF QUALITY,ENVT,OHS &EC

INTEGRATED MANAGEMENT


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Change is certain, progress is not

Thanks for attention

S Kannan +91 96552 41599AMSET Energy, Trichy

www.amsetenergy.in

Energy Efficiency-From a Process Perspective

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