Transcript (Download) - Petroleum Conservation Research Association

WELCOME
DATE : 25/11/04
1
Who
Moved
My Oil ?
2
EMERGENCE OF PCRA
 1973
: OIL CRISIS WORLD OVER
 STUDY
TEAM
: ENGINEERS FROM IOC, NPC, DGTD
ESTIMATED HUGE OIL CONSERVATION
POTENTIAL IN INDUSTRIES & STUs
: CONSERVATION POTENTIAL
OF 20 - 30%
 STUDY
RESULTS
 6th JAN ’76 : PETROLEUM CONSERVATION ACTION
GROUP (PCAG) FORMED
 10th
AUG’78
: PCAG RECONSTITUTED AS
“PETROLEUM CONSERVATION
RESEARCH ASSOCIATION” (PCRA)
AND REGISTERED AS A SOCIETY
UNDER MOP&NG
3
SECTROAL APPROACH
COMMERCIAL
INDUSTRY
AGRICULTURE
PCRA
TRANSPORT
DOMESTIC
4
SCOPE OF ENERGY AUDIT
Sectoral Consumption of Energy (350 MMtoE)
100%
Others (14%) 49 MMtoE
Domestic (10%) 35 MMtoE
80%
Agriculture (5%) 17.5 MMtoE
Transport (22%) 77 MMtoE
DTP &MDP
60%
40%
Industry (49%) 171.5
MMtoE
Energy Audit
20%
0%
1
71% of the Energy Consumption comes under the ambit of PCRA
5
A GIST OF FIELD ACTIVITIES.
S.
No.
Activity
Nos.
(Since 1985)
1.
Energy Audits, Fuel Oil Studies, SSI, Follow ups
34910
2.
Institutional training programme
1102
3.
Model Depot Projects
1696
4.
Driver Training Programme
4014
5.
Rectification of LIPs & footvalves
30212
6.
Demonstration Centre
411
7.
Exhibitions, Seminars & Consumer Meets
945
8.
Action Group Meetings
208
9.
Youth Programme
6819
10. Van Publicity
3537
6
INCREMENTAL SAVINGS - ALL SECTORS
400
350
275
300
250
VALUE
(Rs.Crs.)
220
200
QTY
(‘000 TONNES
150
100
QTY
VALUE
50
7
8
9
0
1
2
3
4
5
6
7
8
9
0
1
86-8
87-8
88-8
89-9
90-9
91-9
92-9
93-9
94-9
95-9
96-9
97-9
98-9
99-0
00-0
YEAR
01- 0
2
02- 0
3
03- 0
4( P)
6
85-8
0
7
RECURRING SAVINGS –
INDUSTRIAL SECTOR
1000
952.23
900
Qty
(‘000
Tonnes)
800
700
600
701.00
500
VALUE
(Rs.Crs)
400
300
QTY
VALUE
200
100
0
85-86 87-88 89-90 91-92 93-94 95-96 97-98 98-99 99-00 00-01 '01-02 '02-03
YEAR
'0304(P)
8
PHILOSOPHY OF ENERGY AUDIT
 Through energy audit, we optimize the consumption of
fuel i.e. coal, electricity petroleum products etc.
 To spread the benefits obtained through Energy Audit
in any one industry to entire cluster
 To replicate the benefit obtained through Energy Audit
in other industries through Education Campaign and
ITPs
 Sponsor R &D projects identified from Energy Audit.
9
Energy Audits in Clusters
(2001-02 to 2003-04)
Sl. Name of the Cluster
No. Industry
1
Aluminium
2
Iron & Steel
3
Cement
4
Pulp and paper
5
Sugar
6
No. of
Industries
Audited
Annual Energy
Consumption
(KLOE)
Saving
Potential
Identified
(KLOE)
5
13570
936
62
133677
16276
2
37786
722
11
58297
3561
1
1450
290
Textile
49
153770
6749
7
Chemical
30
56642
3366
8
Process Industries
131
290718
16882
9
Thermal Power Station
1
1800
257
10
Commercial Buildings
58
19199
1823
11
Hand Tools Industry
28
11020
1888
12
Milk Processing Industry
20
24311
1676
13
Food processing Industry
29
59771
4812
14
Petroleum
80
4930354
82643
15
Engineering
97
1172053
17326
16
Misc.
Total
1
604
272
6964417
17
159206
10
MAJOR ENERGY AUDITS
(Since 2001)
Sl
No
Name of Industry
Type
Savings
Identified
(SI) KLOE
% SI/
EYC
1.
ONGC
Natural Gas
P
Uran, Mumbai
128891
20834
16
2.
IOC Blending Ltd.
LO Blending
P
Vashi,
Mumbai
1750
205
12
3.
IOC LPG Bottling
LPG Bottling
P
Bhopal
1000
200
20
4.
LPG Recovery
Plant, GAIL
LPG
Recovery
P
Lakwa,
Assam
22470
2000
9
5.
HPCL, Nagaon
Paper Mill
Paper Mill
P
Nagaon,
Assam
1600
190
12
6.
Vishnu Chem (Units
I & II)
Chemical
P
Medak, A P
4120
900
22
7.
Mother Dairy
Dairy
P
Delhi
1229
43
3
8.
India Habitat Centre
Office
M
Delhi
1338
96
7
9.
Star Wire India Ltd
Steel
E
Ballabhargh
1247
61
5
TELCO
Automotive
E
Jamshedpur
10000
**P = Process; E=Engg; T=Textiles; G=Glass; M=Miscellaneous
*EYC indicates Estimate I Yearly Consumption of audited industrioes
975
10
10.
Audit
Type**
City
*EYC
KLOE
11
MAJOR ENERGY AUDITS
(Since 2001)
Sl
No
Name of Industry
Type
Audit
Type**
City
*EYC
KLOE
Savings
Identified
(SI) KLOE
% SI/
EYC
11.
TVS Motor Co.
Automotive
E
Hosur,
Karnataka
7920
715
11
12.
Security Paper Mills
Paper Mill
P
Hoshangabad,
MP
11300
1840
16
13.
JK Pharma Chem Ltd
Pharmaceuticals
P
Cuddalore, TN
8000
500
6
14.
UPRVUNL
Power
E
Anpara, UP
4776
232
5
15.
Ginni Filaments
Textile
T
Chhata, UP
13200
827
6
16.
Hans Metals P Ltd.
Metal
E
Kanpur, UP
2000
218
11
17.
Hindalco Ind. Ltd
Aluminium
E
Renukoot, UP
4476
498
11
18.
Maxlux Glass P Ltd.
Glass
P
Uluberia, WB
2448
345
14
19.
Hindustan Iron &
Steel Co. Ltd.
Steel
E
Kolkata
1400
123
9
20.
Britania Industries
Biscuit
P
Kolkata
1920
29
2
**P = Process; E=Engg; T=Textiles; G=Glass; M=Miscellaneous
*EYC indicates Estimate I Yearly Consumption of audited industrioes
12
Energy is Life
Conservation is instinct of life
GDP is inseparable from conservation /efficiency
Who are the Stake Holders?
13
ATMOSPHERE
ENVIRONMENT
HYDROSPHERE
BIOSPHERE
FACTORY
PRODUCT MIX
LOGISTICS
MARKETS
CONSUMERS
PROCESS
MACHINERY
SCALE
QUALITY
SAFETY
STAFF
COMMUNITY
GOVERNMENTS
POLICY
LAWS
REGULATORS
INDUSTRY
ASSOCIATIONS
COMMERCE/BUSIN
ESS/TRADE
IMPORTS /
EXPORTS
ECONOMY/
FINANCE/ BANKING
VENDORS
TAXES /
INCENTIVES
INPUTS
PROFITABILITY
14
Energy is :
 Food, Fodder , Fiber, Fuel
 Health
 Safety
 Climate
 Any greater cause than energy
conservation?
15
Who
Moved
My Water?
16
 Energy is Consumed for emotional uplift like
consumerism, competition, convenience,
comfort, life style, luxury etc.
 Energy & energy conservation is an issue of
1.
2.
3.
4.
Attitude
Values
Beliefs
Practices
17
 Energy is an Emotion more than Knowledge
•
The T&D losses in Mumbai, Calcutta & Delhi
are 10-11%, 18-19% & 30% respectively. In
certain states it is 50%
•
Russia took 12 years to ratify Kyoto Protocol
•
USA is not convinced yet to ratify Kyoto
Protocol
18
Energy & Resources
 50 years back we knew Drinking Water was
free. Today it is NOT
 Drinking water extraction in future may use oil
drilling like technology and vast process plants to
make the water potable.
 Where is the energy for this future?
19
Energy & Resources
All of us believe today that Air is Free. Will
it follow the route of Drinking Water in
future?
For combustion and release of energy, air is
as important as fuel if not more. How many
of us measure and control the combustion
process in totality ?.
20
Energy & Resources
How many of us check the air filter vis-àvis the fuel tank level of our automobiles ?
Can you risk to Guess , billions of US
dollars of packaged air in future and the life
forms?
21
Who
Moved
My Air?
22
PCRA’s Mixed Experience
 Enlightened industry is employing OEMs &
Technology suppliers to do Energy Audit at
regular intervals
 MNCs are conducting Energy Audits of their
vendor’s units over decades
 Tea, Salt & Chemical Industry using water
circulators or thermic fluid heaters to preheat air
as a via media
23
PCRA’s Mixed Experience
 Hotels are generating hot water from DG set hot
flue gas. Hotels are using boilers to generate steam
and run vapour absorption refrigeration systems
 A very enlightened salt industry using vacuum
flash for drying salt. Producing pure water &
conserving ground water. A two in one salt
manufacture cum desalination! Or is it Three in
One?
24
PCRA’s Mixed Experience
Some industries still are ignorant and
secretive. Unwilling to allow the energy
auditors to see the process, plant, quality
control deptt etc. They still believe energy
conservation is on boiler floor and motor
drives only
25
PCRA’s Mixed Experience
 The garbage collector’s van getting filled fastest.
Sometimes some houses remain uncollected. The
garbage collector wades through the traffic in
search of easy / quick dumping grounds. Now the
house holder is waiting in advance for the
garbage collector to deposit / dispose off his
consumption.
 An increasing tendency of the industry to consume
wood in boilers/ furnaces in place of oil/ coal
26
Who
Moved
My Coal ?
27
PCRA’s Experience
 PCRA does the scoping study, meeting &
discussing with people, process study, equipment
wise study, literature study etc before detailed
energy audit. In a way we establish full
communication by knowing the language of the
industry.
 In a textile spinning mill the exhaust fans were of
overcapacity compared to inlet fans
28
PCRA’s Experience
Selection of suitable number of inlet fans,
water spray pumps, exhaust fans along with
relative humidity measurement saved 2.5
lacs KWh/Annum
29
PCRA’s Experience
 Air compressor appears to follow 80:20
principle. It delivers only 20% effective output
and wastes 80% of the input. Due to
- Deteriorated performance of internals
- Compressed air leaks
- Air pressure selection
- Single stage operation
30
PCRA’s Experience
 - Inter stage coolers
- cooling Water Treatment
- Cooling Tower Performance
- Pressure drop
31
PCRA’s Experience
- In a dry cell manufacturing plant one of
the four compressors could be stopped
- 5% of the electricity generated in the country
runs air compressors
 In a foundry the used sand of moulds is recycled
after removal of organic binders and flux. The
dryer used for this purpose was kept over fired to
be on the safe side. An appreciation of quality
measurement of fresh and recycled sands reduced
the fuel consumption.
25.11.04
32
PCRA’s Experience
A steam less dairy that uses only hot water
circulation. No boiler, no steam.This dairy
does not have milk powder in the product
mix
25.11.04
33
PCRA’s Experience
 Optimizing refrigeration loads in a dairy.
20% of refrigeration loads were reduced by
- off peak operation of refrigeration for
ice build up in IBT
- Sequencing of IBT operation & avoid
unnecessary ice build up with respect
to stocks & expected inputs
34
PCRA’s Experience
- Control of ice build up to maximum 2 inch
- Automatic instrumentation for heating
and chilling to avoid over heating / fouling
& over chilling/ too low suction pressure.
- optimum insitu cleaning to improve
regeneration efficiency. Save
water/chemicals too
35
PCRA’s Experience
- Monitoring and adjusting cooling tower
for the rated range and approach. This
alone controls the Discharge Pressure of
the compressor
- Calculate regeneration efficiency in every
shift. Aim for 90%
36
PCRA’s Experience
 In a Mirinda Orange Drink Plant found that it’s CO2
absorption requirement was half compared to exotic
Coco-Cola. Higher temperature of chilling for the desi
drinks are enough. Different energy settings for
different product mix.
 In a latex plant the OEM has set the chiller at +6 0 C of
product temperature. The process needed higher
temperature of 16 0 C! In operation, the product was
shock chilled and allowed to thaw!! A good example of
energy conservation at the interface of the equipment
and process. The machine needs reset for a product
outlet temp of 16 0 C.
37
PCRA’s Experience
An FMCG major was connected from an
agricultural feeder. The voltage fluctuation
causing recurrent disruptions. They were
running DG sets at 20% load factor and
disconnected the EB feeder. Suggested lock
rotor protection/ re-acceleration after carrying
equipment wise no load / part load/ full load
readings. The EB feeder was revived. DG set
shutdown.
38
PCRA’s Experience
 In an asbestos plant, the asbestos, cement and fly
ash slurry is processed in a vacuum drum filter for
required thickness of sheets. The vacuum pump
discharge temperature is 80 0 C. Suggested to
utilize this waste heat to dry the sheets and reduce
fuel firing and electricity
Amazing, is it not?
Lot of low lying fruits!
39
OPPORTUNINITES GALORE
TOP 10 PRIVATE COS ACCORDING TO POWER & FUEL COST(Rs. Crores)
COMPANY
POWER & FUEL
03-04
02-03
%
Ch
P&F/Tot Exp (%)
03-04
02-03
ESSAR STEEL
1108
873
26.9
38.8
38.3
GRASIM IND
889
856
3.9
22.6
23.7
ACC
744
706
5.4
25.6
27.5
RELIANCE IND
725
719
0.8
1.8
2.3
TISCO
668
788
-15.3
9.0
11.8
CHAMBAL FERT
554
481
15.2
30.5
31.7
CENTURY TEXTILES
495
466
6.3
25.5
25.3
GUJ AMBUJA CEM
431
324
32.9
34.2
34.5
BALLARPUR IND
412
384
7.3
26.5
34.0
INDIAN ALUMINIUM
378
347
9.0
27.8
29.3
14780
13694
7.9
8.9
9.6
TOTAL(201)
25.11.04
Ref.Financial Express, Chennai 22.06.04
40
Who
Moved
My Electricity?
41
Concepts for Future
Individual Carbon Neutrality
Distributed Production for Distributed
Consumption
Asymptote Nature?
Ecological
Degradation
But ………
Production Engages
People + Locations
42
Concepts for Future
 Food Miles
 Up-gradation / harvesting of low grade energy
sources (sun light, low temp.heat of flue gas
from boiler, furnace, engines, low velocity wind
by thermo compressors, heat pumps etc)
 Awakening on common property rights of air,
water, earth, sky….
43
Concepts for Future
 Conflict resolution between interest holders of
food, fibre, fodder, fuel
 NPT on automobiles
 Nuclear power for H2 production / desalination
 Recycling industries for ferrous/ non-ferrous
metals, plastics, paper etc.
44
Concepts for Future
 Consumers shall pay for the cost of pollution
(producer shall pay …..is past)
 Press the Best Individuals, Institutions,
Organizations, & Resources for energy
conservation. e.g Brand Ambassadors of the
FMCG, Media, Chartered Accountants etc. This
will ensure sustainable business as well as life
45
Concepts for Future
ICAI published a book on energy audit and
management.
46
Concepts for Future
Enjoy the interest on the principal of
nature’s bounty. Do not treat it as booty.
Mankind should not be the worst NPA
amongst the life forms.
47
Save Energy
Save Yourself
48
LINK
49