Fuel Bill in your plant with
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Transcript of Fuel Bill in your plant with
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Knowledge Based Software for Thermal Energy Conservation
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We all are Looking for Sustainable Solutions to following PROBLEMS?
Pressure on Profit Margins due to High Competition & High Production Cost
Knowledge level of Plant Personnel on Thermal Energy Efficiency & Training
Managing Equipment Specifications and their History Cards
Finding & Implementation of Cost Reduction Measures (CRM) as a regular activity
Increasing Energy Cost
Unaware of the losses & potential for energy cost reduction in the plant OR some known ideas/concepts needs further feasibility analysis before implementation
Taking Initiative & Building Team Effort for Energy Cost Reduction
Relying on external energy audits only
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We all are Looking for Sustainable Solutions to following PROBLEMS?
How to solve them effectively? Is there a collective solution?
Looking for Energy Consumption Norms Fixation & Targets
Wants to verify saving potential offered by energy efficient equipments/controls
Arriving at Equipment selection criteria so as to ensure high efficiency on operation for utilities like Furnaces & Boilers
Wants to establish proper Energy Monitoring approach to know & control Energy (Steam/Fuel) Consumption at various sections/equipments
Looking for a tool to quantify saving potential & implementation of energy conservation idea
Wants to facilitate ISO 18000
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Does the Equipments stand to the desired specification or requirement
Is the Equipment operating at the Designed Efficiency
Which are the major Losses contributing to the Inefficiency
What are the ways to Quantify these Losses
How can these Losses be minimized
How much is the savings achieved by minimizing these Losses
What is the Steam Generation Cost
What are the Fixed Steam Losses
How much do I need to spend on Insulation and the Savings achieved
Is the option of alternative Fuel feasible
What is the quantity of Flash steam I can generate
What is the Percentage Recovery of Waste Steam being reutilized
Do I need to Derate my Boiler
How much I am losing due to Inappropriate Fuel Handling and
Transportation
We also need to answer following questions for effective ENERGY COST MINIMIZATION
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• What are the major Losses in Fuel Fired Furnaces
• What is time for which my furnace remains Idle between Successive Batch Loading What should be the temperature of Exhaust Gas from Chimney
• How can I Save by Implementing Waste Heat Recovery
• How much is the Radiation Loss in my Furnace
• How can I increase the Efficiency of my Furnace
• What are the major Losses in Drier
• What are the Energy Conservation Opportunities available
• What is the Efficiency of my Distillation Column, Evaporator
• What are the Energy Saving options available to increase the Efficiency of my Distillation Column, Evaporator
• How Efficient is my Thermic Fluid Heater, Reactor
Questions need to be answered ?
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• Understanding the fundamental specification of the equipment's utilizing Thermal Energy
• Determining the Efficiency of the Equipment
• Analyzing the Losses and the ways to minimize them
• Maintaining the Achievable Efficiency of the Equipment
• Making Cost Effective Economic Decisions
• Energy Conservation Opportunities and the Savings Achieve
• Reducing the Cost of Production
How See-Thermisave can help you?
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As BEE explain: You as Energy Manager
Focal point of all the activities pertaining to energy management in the organization
Establish an energy conservation cell
Develop & manage training program for energy efficiency at operating levels
Prepare Annual Activity Plan
Develop integrated system of energy efficiency and environmental improvement
Establish/participate in information exchange with other energy managers of the same \sector through association.
Provide information to BEE & Designated Agency of the respective states as demanded in the Act
Co-ordinate implementation of energy audit/efficiency improvement projects through external agencies Initiate activities to improve monitoring &
process control to reduce energy costs
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Sustained energy conservation efforts Plant energy usage needs to be evaluated on regular & continual basis Ensure energy efficient working of the factory at equipment, utility, process & plant level Continual improvement in establishment’s energy performance levels
A strategic approach to accomplish this would involve:
Creation and maintenance of a detailed database from equipment design specification to the operating parameters;
Create Benchmarks & Monitor Energy Consumption with reference to it;
Facilitate Identification of Energy Conservation Opportunities on a continual basis;
Facilitate evaluation of Techno-Economic Feasibility of these Opportunities; Facilitate Implementation of the Measures; Monitoring, Verification & Reporting the Savings.
Knowledge based software solutions…. Facilitates you….
That means…...
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What See-ThermiSave can do for you? – its Features
Boilers
Regular Monitoring of Equipments Ensures BEST way of Optimum Energy Utilization in Plants
1 Recording Fuel receipt & determining deficits if any, Storage accounting and Pre-heating/ pre- conditioning Requirements; implementation better fuel management practices
2. Incorporating Boiler specification & comparison with norms: a must have information for energy conservation efforts
3. Observation table for boiler efficiency tests: User takes the printout & caries out the test
4. Direct efficiency test calculations: The output also includes Evaporation Ratio (Kg of steam/Kg of fuel) & Steam Cost (Rs/Kg)
5. Indirect efficiency test calculation: Also displays % excess air (By CO2/O2), %Dry gas loss, %Wet gas loss, %Blowdown Loss
6. Choice of fuel for Steam Generation: To ascertain lowest steam cost
7. Savings by reducing Dry Gas Loss through excess air reduction & Stack Gas temperature
8. Savings in Ash loss by reduction in un-burnt Carbon & Waste-heat recovery options
9. Idling losses due to oversized boilers (Derating of boilers for savings)
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What See-ThermiSave can do for you? – its Features
Furnaces
1. Incorporate specification for furnace with & without Chemical Reaction, Batch/Continuous, Steam/Fuel fired, Rectangular/Cylindrical
2. Measurement of Furnace Efficiency (Direct & Indirect): Also computes %Radiation loss, % Loss due to Moisture %Dry gas loss, %Wet gas loss, heat carried away by product, Avg. fuel consumption; Documents ID & FD fan power consumption; Ensures fuel properties
3. Energy conservation by Feed screw / loading improvement
4. Waste heat recovery options through Economizer and Recuperator
5. Energy conservation by Reduction in furnace volume
6. Selection of insulation to minimize Radiation Loss; Product heat recovery to save energy
7. Batch versus continuous furnace to obtain higher productivity
8. Moisture reduction in Feed for quicker production & higher output
Choice of fuel has done wonders in Energy Cost Minimization
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SEE-Tech Solutions Pvt. Ltd.
Approach in See-ThermiSave
See-ThermiSave Offers
Output you Get Additional Benefits
MODULES
Boilers (Oil Fired, Coal Fired & Non IBR)
Furnace (Without & With Chemical Reaction)
Thermic Fluid HeaterDrier (Steam & Oil Fired)
ReactorDistillation Column
Evaporator
Functional Help: Simplified Test Methods, Transparent Formulae & Calculations,
Input forms to ensure correct & complete data collection, Instruments
Required
Monitor Specific Energy Consumption
at Equipments as compared to Benchmark
Performance evaluation Of the equipments, Operational Efficiency
(Direct & Indirect), SEC, Comparison with Benchmark. Quantified Losses
Applicable energy conservation Options. Potential for Energy
Conservation. Savings in kWh & RsTechno-Economic Feasibility, Pay-
back Period, Life Cycle Costing, Merits & De-Merits of Various EC
OptionsTechnical help
On Each equipment
Monitoring Energy Performance & Savings after Implementing ECM
Energy efficient Equipment Vendors list
Summarization of ECM for Management Reporting
Elaborate subject knowledge of EE &
Proven Pathway for Energy Conservation for all the
modules
Implemented Case-Studies
Complete Equipment Specifications at one place,
Fuel Receipts, Storage Tanks, Fuel Consumption
Monitoring
And a lot more
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Plant Particulars
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What Parameters I
Need for performance Evaluation ?
Do I Monitor
Fuel Receipts
?
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Monitor Fuel consumption
Equipment wise
Monitor Fuel Properties &
Quality
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Oil Fired Boiler: Steam Cost,
Direct & Indirect Efficiency
Click F1 for Approach Adopted & Formulae
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Do I Monitor Specific energy Consumption Per Product ?
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Coal Fired Boiler: Direct & Indirect
Efficiency
Know Steam Cost,
Evaporation Ratio & Losses for the IBR, Non
IBR Boilers
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Boilers: Savings by
Reducing Stack Gas
Temperature
Boilers: Savings by Reducing Excess Air
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Savings by Insulating Bare
Pipes
Ideal Condensate
Handling Methods
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Performance Evaluation of Thermic Fluid
Heater
Dryer; Steam, Coal & Oil
Fired
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Furnaces: without & with
Chemical Reactions
Direct & Indirect
Efficiency of Furnaces
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Performance Evaluation of
Reactors
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Performance Evaluation of Evaporator
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Distillation Column, Reboiler,
Condenser: Performance Evaluation
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Technical Help for Energy Conservation
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For further information contact :
SEE-Tech Solutions Pvt. Ltd.,LetsConserve, 11/5, MIDC Infotech ParkNear VRCE Telephone Exchange,South Ambazari Road, Nagpur - 440 022. M.S.
Ph : +91-712 - 2222177Fax : +91-712 - 2225293E-mail : [email protected] us at : www.letsconserve.org