7/30/2019 Energy Efficiency-From a Process Perspective
1/46
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
7/30/2019 Energy Efficiency-From a Process Perspective
2/46
Presentation structure
EnergyLaws/Basics
Energy costs/prices
Energy-Process
Energy in Textile sector
Energy Audits
Future Energy
About AMSET
Back to Basics
7/30/2019 Energy Efficiency-From a Process Perspective
3/46
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.
7/30/2019 Energy Efficiency-From a Process Perspective
4/46
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
7/30/2019 Energy Efficiency-From a Process Perspective
5/46
7/30/2019 Energy Efficiency-From a Process Perspective
6/46
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
7/30/2019 Energy Efficiency-From a Process Perspective
7/46
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.
7/30/2019 Energy Efficiency-From a Process Perspective
8/46
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
7/30/2019 Energy Efficiency-From a Process Perspective
9/46
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
7/30/2019 Energy Efficiency-From a Process Perspective
10/46
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
7/30/2019 Energy Efficiency-From a Process Perspective
11/46
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
7/30/2019 Energy Efficiency-From a Process Perspective
12/46
7/30/2019 Energy Efficiency-From a Process Perspective
13/46
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
7/30/2019 Energy Efficiency-From a Process Perspective
14/46
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
7/30/2019 Energy Efficiency-From a Process Perspective
15/46
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
7/30/2019 Energy Efficiency-From a Process Perspective
16/46
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
7/30/2019 Energy Efficiency-From a Process Perspective
17/46
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%
7/30/2019 Energy Efficiency-From a Process Perspective
18/46
Heat Energy Consumption in aComposite Mill
Steam
Distribution
Network
10%
Boiler Plant
25%
Humidi-
fication &Others
15%
Dyeing &printing
15%
Bleaching &
Finishing
35%
7/30/2019 Energy Efficiency-From a Process Perspective
19/46
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
7/30/2019 Energy Efficiency-From a Process Perspective
20/46
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..
7/30/2019 Energy Efficiency-From a Process Perspective
21/46
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-
7/30/2019 Energy Efficiency-From a Process Perspective
22/46
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.
7/30/2019 Energy Efficiency-From a Process Perspective
23/46
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
7/30/2019 Energy Efficiency-From a Process Perspective
24/46
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.
7/30/2019 Energy Efficiency-From a Process Perspective
25/46
7/30/2019 Energy Efficiency-From a Process Perspective
26/46
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.doc7/30/2019 Energy Efficiency-From a Process Perspective
27/46
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.
7/30/2019 Energy Efficiency-From a Process Perspective
28/46
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.
7/30/2019 Energy Efficiency-From a Process Perspective
29/46
7/30/2019 Energy Efficiency-From a Process Perspective
30/46
Future Energy
The best is the enemy of the
good
7/30/2019 Energy Efficiency-From a Process Perspective
31/46
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.
7/30/2019 Energy Efficiency-From a Process Perspective
32/46
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!!.
7/30/2019 Energy Efficiency-From a Process Perspective
33/46
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.
7/30/2019 Energy Efficiency-From a Process Perspective
34/46
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
7/30/2019 Energy Efficiency-From a Process Perspective
35/46
7/30/2019 Energy Efficiency-From a Process Perspective
36/46
AMSET Energy Systems &Solutions Private Limited,Trichy
-team of Energy
Auditors/Managers certified byBureau of Energy Efficiency
7/30/2019 Energy Efficiency-From a Process Perspective
37/46
AMSET Energy
Agriculture
Manufacturing Existing Economy
Services
Experiential Future contributors
Transformational
Energy is used everywhereE=mc2
7/30/2019 Energy Efficiency-From a Process Perspective
38/46
AMSET Energy- vision
Enable Businesses to reduce Energy
costs, by involving People, contributing to
Profits and better Planet
7/30/2019 Energy Efficiency-From a Process Perspective
39/46
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
7/30/2019 Energy Efficiency-From a Process Perspective
40/46
The product of a
Consultant should beresults for clients-NOT
reports
7/30/2019 Energy Efficiency-From a Process Perspective
41/46
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.
7/30/2019 Energy Efficiency-From a Process Perspective
42/46
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..
7/30/2019 Energy Efficiency-From a Process Perspective
43/46
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
7/30/2019 Energy Efficiency-From a Process Perspective
44/46
7/30/2019 Energy Efficiency-From a Process Perspective
45/46
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
7/30/2019 Energy Efficiency-From a Process Perspective
46/46
Change is certain, progress is not
Thanks for attention
S Kannan +91 96552 41599AMSET Energy, Trichy
www.amsetenergy.in
Top Related