Background
PGS ENERGY SERVICES PVT. LTD established in 1997 as Accredited Energy Audit firm &
ESCO for various energy efficiency/conservation projects of Industry, Commercial buildings
& MCs. Our areas of expertise includes a broad spectrum of consultancy & Implementation
of EC projects. PGSEPL is also registered as Micro Small & Medium Enterprise with NSIC
Empanelment : BEE UNDP EESL SIDBI PEDA HAREDA GEDA MEDA H.P SDA Odisha SDA ASDA AAI DRDO Chandigarh Admin
PAT : Since 2007 Cement, Textile, Iron & Steel, Chlor-Alkali, TPP, Pulp & Paper, Fertilizer EAs : BEE|EESL|NESTLE|HAFED|AAI|PEDA|SDAs|HOSPITALS|HOTEL 2009 : Successfully Implemented 1st LED Street light project in India Jan Marg, Chd & Majitha PB IGEAs & ESCO : Chandigarh Administration |SDAs| RENEWABLE : Solar Projects|Punjab & Haryana Raj Bhawan| Judicial academy Chd |Pb. Civil Sectt.| Haryana assembly, U.T – Sectt. Chd.
Cement
ACC Limited
Ambuja Cements ltd, Ropar
Ambuja Cements ltd, Darlaghat
Birla Corporation ltd
HeidelbergCements India Ltd
JK cement Works
Chanderia Cement Works
Paper & Pulp
Satia Industries Ltd
BILT Papers Ltd
Bindals Papers Mills Ltd
Yash Papers Ltd
Ruchira Papers ltd
Dev Priya Products Ltd
Naini Tissues Ltd
Shree Shyam Paper Mills
Textile:
Vardhman Group
Winsome Yarns Ltd.
Reliance Industries Limited
Grasim Industries
Arvind Ltd.
Birla Century
Ashima Ltd. Spin fab
Ashima Ltd. Denim
Hisar Spinning Mills
Soma Textiles & Industries
Rainbow Denim Ltd.
Suzuki Synthetics Pvt. Ltd
Suzuki Suitings Ltd.
Shree Rajasthan Syntax Ltd.
BMD Pvt. Ltd.
Fertilizers
IFFCO, Gujarat
IFFCO, Odisha
FACT, Kerela
SPIC, Tamil Nadu
Madras Fertilizers ltd
GSFC, Sikka
GSFC, Vadodara
GNFC, Gujarat
Mangalore Chemicals & Fertilizers Ltd.
Rashtriya Chemicals Ltd.
Paradeep Phosphates ltd
SIEL Chemical Complex
Tata Chemicals ltd
National Fertilizers ltd
Coromandel International Ltd. Vizag
Coromandel International Ltd. Tamil Nadu
Deepak Fertilizer & Petrochemicals Corpn. Ltd
.
Kanpur Fertilizers & Cement Ltd.
Zuari Agro Chemicals ltd
Iron & Steel
Anjani Steels ltd
Singhal Enterprises ltd
Top Worth Iron & Steel
Crest Steel & Power
Thermal Power plant
Yamunanagar TPP
Panipat TPP
NTPC Ltd.
Contents 1. Case Study: Pulp & Paper Sector Strategies for EE & ENCON Approaches
2. Case Study: Cement Sector EE with zero investment
3. Case Study: Building EE project ESCO project
4. Case Study: Iron & Steel Sector Optimization Strategies for EE
Case Study: PULP & PAPER INDS.
Satia Paper Mills, Muktsar (Punjab)
Energy Efficiency strategies adopted: Achievements Quantified
1. Modification in Paper machine (press and wire part) 3350 Mtoe
a. Steam saved = 9900 tonne (annual) ~ 10% 936 Mtoe
b. Fuel saved = 2600 tonne/yr
c. Dryness = 3% increase
d. Production = 6 tonne/day increase~1980T/yr 1736 Mtoe
e. M/c Speed = 50 rpm increase ~ 51% of more
Press part modification for enhanced water removal Hydronip, Hydraulic pistons
Press Roller Change
Contt……….
Energy Efficiency strategies adopted: Achievements Quantified
2. Modifications in Vaccum pumps 29.455 mtoe
a. Header modifications 100 kW
b. Pump/ Motors replacements 345 kW
c. Shutting OFF 3 vaccum pumps (usage = 1 pump)
8.6 mtoe
3. Commissioning of H.P Boiler (490°C)
a. increase in evaporation ratio = 3.8 to 3.9 t/t
b. fuel saved = 3.16 % ~ 4189 tonne/yr
Total savings 1508.22 mtoe
Case Study: PULP & PAPER INDS.
Ruchira Paper Mills
ENCON Approach Benefits/ savings
1. Close loop arrangement for bucket elevator Rs. 7.5 lacs energy cost/yr
BENEFITS:
a. Furnace efficiency improvement 0.14%
b. ID Fan load reduction 84 KWH per day
c. Steam saved 39 tonne per day
d. Manual labour cost cutting Rs. 8000 monthly
e. Fuel saved 0.5 tonne per day
ENERGY SAVINGS 2.6MTOE
Contt………..
ENCON Approach (Year 2016) Benefits/ savings
2. Heat Exchanger (3 no.s) ~ Black liquor Rs. 2.94 crores~year 1
a. Temp recovered 85° C
b. RO water temp increase 35 °C
c. Steam saved 80 tonne/day
d. Total savings 6.96 MTOE
Initial and present scenario comparison
Energy Consumption before Heat exchanger 1197980 mkcal
Energy Consumption after Heat exchanger 1179764 mkcal
SAVINGS 18216 mkal
Case Study: Cement Sector
Ambuja Cement, Ropar (Punjab)
Energy Conservation measures Savings Achieved
Increase of biomass usage in place of coal (16 % to 40%) 43,461 mtoe
a. Optimisation of excess air in boilers (33% to 30%) 3083 mkcal
b. Improvisation in CHP, saving in electrical power f for coal crushing & Grinding
984 mkcal
c. Sensible heat savings due to lower flyash (3965 tonne ash) 3230 mkcal
Installation of sonic soot blower~dislodging ash deposit 30,521 mtoe
a. Energy savings 6985.2 mkcal
b. Decrease in fuel consumption 2% approx.
Contt….
Energy Conservation measures Savings Achieved
Bottom Ash draining via bed ash cooling ~ recoversensible heat from hot bed material
92,020 mtoe
a. heat loss savings in bottom ash (coal) 133 kcal/kg coal
b. heat loss savings in bottom ash (biomass) 45 kcal/kg biomass
Improvisation in packing plant/ interlocking in bucket elevator
54747 mtoe Rs. 1.33 crores
a. Increase in production 11 MT/hr
b. Reduction in electrical power consumption 1663447.26 kWh
c. Reduction in running hours 3473 + 2609 Hrs.
Improvement = arresting air leakages + stopping the idle running during shift change +extraction blockage cleaned in silo
Case Study: Cement Sector
Diamond Cement Ltd. HCIL, Damoh
Energy Conservation measure adopted Energy Savings
1. Installation of WHR System 1,01,146 mtoe
Benefit:
a. Recovery of waste heat from 3 kilns 250-300°C Recovered
b. Energy Savings 118.80 Mio kWh
c. Annual Cost savings Rs. 784 millions
Investment Rs. 1890 millions
Payback 2.4 years
ESCO Project
As part of an initiative to reduce energy cost and consumption, SDA secured the services of PGS Team to
perform an energy audit and prepare a detailed project report of Office Building in an effort to develop com
prehensive Energy Conservation and Retrofit Measures (ECRMs).
Case Study: Building
Previous Present
Type Annual Energy consumption (kWh) Type Annual Energy consumption (kWh)
T-12 Double Fixture 10108.80 20 W*2 LED Tube Light 3888.00
T-12 Single Fixture 2920.32 20 W LED Tube Light 1123.20
Old Ceiling Fan 2395.00 BEE five Star Rated Ceiling Fan 1530.00
Old 1.5TR Split AC 33364.80 BEE five Star Rated 1.5 TR Split AC 26092.8
Total 48788.92 Total 32634
Previous & Present Annual Energy Consumption Scenario
Case Study: Office Building
Energy Savings in terms of MTOE & Avoided Capacity Generation
As a result of implementation of the aforementioned ECRMs, the state would be able to avoid a
capacity addition (MW) to cater this reduction of load. This is calculated in terms of Avoided
Capacity Generation (MW) using the formula given below:
• Total Annual Energy Savings : 16,055 kWh
• Avoided Capacity Generation for SDA Building (in MW) = 0.0145 MW
• MTOE savings = 1.38
Impacts on reduction of Green House Gases (GHGs)- 13.17 Co2 equivalent
Case Study: Steel Industry
Singhal Entreprises Ltd.
Energy Efficiency strategies adopted: Achievements Quantified
1. Reduction of LOI content Rs. 89.84 lakhs
Benefits:
a. Unburnt Carbon loss reduction in ash 4.97 to 3 %
b. Reduction in coal consumption 3 %
c. Improvement in boiler efficiency 3-4 %
Technology used~air velocity, uniform raw material size
2. Reduction in bends~steam line to header Rs. 84 lakhs
a. Reduction in pressure drop 4 kg/cm2
b. Fuel savings 3%
Case Study: Steel Industry
Anjani Steels Ltd.
Optimization techniques for EE Savings Quantised
1. De-staging of Boiler Feed Pump 158400Kwh Rs. 9.5 Lakhs
Removing one stage (From 11 to 10 no.) ~ Discharge Pressure reduction by 6 kg/cm2 (90Kg/cm2 to 84Kg/cm2 )
20kWh
Investment of 1 lac Payback=1 month
2. Rectifying & Repairing the Leakages at SMS Compressor 144000Kwh Rs. 5.04 Lakhs
a. Power saving 1 kWh per leakage
b. Zero investment Immediate payback
Contt…
Optimization techniques for EE Savings Quantised
3. Improvement in Economizer & Air Preheater Efficiency by Cleaning the Tubes & Plugging the Leakages
Rs. 1.497 Crores
a. Heat loss saving due to air ingress
b. Coal consumption reduction (3744 tonne) 5 %
No investment Payback= Immediate
4. Reducing the Unload Set Point Pressure at Rolling Mill Compressor
60480kWh Rs. 3.62 Lakhs
a. Power Savings 12 kWh
b. Pressure reduction (8Kg/cm2 to 7.5Kg/cm2)
No investment Payback= Immediate