Transcript Study on Setting up of Standards & Norms for Energy Usage

Overview of Energy Efficiency Trend in
Industry Sector
(Cement , Iron & Steel and Power Plant)
S.P.Garnaik
Joint Director
Resource Conservation
& Management Division
FICCI, New Delhi
Sectoral Energy Consumption v/s
Contribution to the country’s GDP
Sector
% Energy
Consumption
% Contribution to
GDP
Industry
40
27
Agri, AH & Fisheries
7
19
Commercial & Services
43
54
Household & Others
10
Source : Energy Conservation Guide, PCRA
Reasons for Change in Energy Usage Pattern
Increase
Competitiveness
Regulatory Compulsion
Increase
Awareness About EC
-Change in Technology
-Retrofit Options
-- In-House R&D
--Adoption of EE Techniques
--Fuel Shift
-EC Act 2001
-Energy Audits
-- Separate EC Cell
--NAPCC (NMEEE)
-More Publicity thru
various media
-Concept of CB options
-- NECA
--Rigorous Activities by
various agencies
CEMENT SECTOR
Trend of Installed Capacity & Actual Production (Million Tons)
250
230.27
200
187.61
150
82
100
50
0
92
90
88
86
84
82
80
78
76
74
72
1995-96 1996-97 1997-98 1998-99 1999-00 2000-1 2001-2 2002-3 2003-4 2004-5 2005-6 2007-8 2008-9
Capacity
Production
Cap. Utl.(%)
Source: CMA
148 Major Plants (219.17 mnT) & 11 Mini Plants (11.10 mnT)
Turnover = About 18,500 mn US $ in 2008
India is 2nd Largest Producer of Cement (6% of world) after China
Annual Per Capita Consumption = About 150 kg
Cement Industry – Some Energy Fact File !
Major Energy Source
: Coal and Electricity
Energy Cost
: About 20-40% of total Manufacturing cost
Energy Consumption
: About 14.47 MtoE in 2007-8
No. of DCs
: 104 as on 2008-09 (with more than 30000 mtoe p.a)
SEC
: 3.0 – 3.4 GJ/Ton (World Benchmark 2.9 – 3.0 GJ/Ton)
SEC (Thermal)*
: 665 – 995 Kcal/Kg of Clinker
SEC (Electrical)*
: 66 - 127 KWH/Ton of Cement
Major Energy
Consuming Area
: Clinker Production (about 80% of total)
Source : Energy Guidebook, PCRA
* TEDY, 2007
Bandwidth of SEC (Elect)
16
16
14
13
14
No of industries
12
10
10
8
7
2005-6
7
2006-7
5
6
2007-8
4
2
2
2
0
60-75
75-90
90-100
sp electrical energy consumption in kWh/Ton
Source : NECA
Bandwidth of SEC (Thermal)
14
12
No of industries
10
8
2005-6
2006-7
6
2007-8
4
2
0
less than 700
700-750
750-800
800 and above
Specific thermal energy consumption in kcal/kg
Source : NECA
Trend of SEC (Elect.) of Cement Industries
(KWH/ton)
95
91
88
90
87
84
85
80
75
Data of 38 major industries having
Dry-Process Technology
77.5
76.4
75.2
Source : TERI
Data of 28 major industries having
Dry-Process Technology
70
Source : BEE
65
SEC has reduced by about 1.7% per year
60
1999-00
2000-01
2001-02
2002-03
2005-06
2006-07
2007-08
Trend of SEC (Thermal) of Cement Industries
(Kcal/kg of Clinker)
760
750
748
740
Best SEC : 688.7
742
740
734
730
725.8
720
SEC has reduced by about 1.7% per year
710
725.9
726
SEC has reduced by about 0.3% per year
700
1999-00
2000-01
2001-02
2002-03
2005-06
2006-07
2007-08
Major Energy Saving Initiatives…
NCB energy audit studies carried out in 36 Cement Plants during last
five years indicated potential savings ranging from 4 to 210 kcal/kg
clinker and 0.78 to 27 kWh/tonne cement.
Various Activities:
Comprehensive Energy Audits through CEAs
Formation of Energy Conservation Cell
Adoption in Energy Efficient Technologies
- Waste Heat Recovery
- Co-Generation options
- Use of VRM in place of conventional ball mills, external re-circulation system for
VRMs, high-efficiency separators in grinding circuits etc.
- Installation of pre-calcinators and five or six stage pre-heaters with low pressure
drop cyclones, use of new generation coolers etc.
- Use of VFDs / VSDs
Participation in NECA
THERMAL POWER PLANT
Existing Generating Capacity- March 2008
Fuel wise break-up
(MW)
Sector wise break-up (MW)
Thermal
92,426
63.8%
Hydro
36,033
24.9%
4,120
2.8%
Nuclear
Renewable
TOTAL
12,194
8.5%
144,773
100.0%
Private
Sector
14%
Central
Sector
34%
State
Sector
52%
(Excluding captive capacity of 14636 MW connected to grid)
(All figures provisional from CEA)
Total generation in 2007-08 – 704.45 BU
Energy Shortage
9.8%
737
750
REQUIREMENT
AVAILABILITY
700
8.3%
650
600
550
8.8%
7.8%
7.5%
546
7.1%
7.3%
591
631
665
624
559
579
523
507
548
500
450
9.6%
691
519
483
467
2001
2002
498
2003
2004
2005
2006
2007
DURING 2007-08, PEAKING SHORTAGES WERE 16.6%
2008
YEARS
2007-08
2006-07
2005-06
63
64
.6
67
.3
64
.7
64
.4
78
.61
74
.8
77
.03
72
.2
74
.3
72
.7
69
.9
69
78
2004-05
2003-04
60
61
73
2002-03
2000-02
57
.1
56
.5
68
2000-01
1999-2000
1998-99
1997-98
55
.3
53
.9
55
56
.5
63
1996-97
1995-96
1994-95
1993-94
1992-93
1991-92
1990-91
1989-90
1988-89
1987-88
53
53
.2
52
.4
58
1986-87
1985-86
PLF (%)
PLF at Different Years
48
Per capita Consumption remains low
In 2006
India
Egypt
China
Brazil
665
618
NATIONAL ELECTRICITY POLICY
TARGETS PER CAPITA
1,465
AVAILABILITY OF 1000 KWH BY 2012
1,684
2,340
Russia
6,425
Germany
7,442
Japan
8,459
USA
World Average
14,240
2,701
Source: UNDP Human Development Report 2007-08 – Data for 2004
Figures in kwh
Power Plants have Focused in
Reduction in APC
Improvement in HR
(from 10% to 7%)
(improved by 12%)
Indian scenario: Design Heat rate
Period
Steam pressure
Unit size
(MW)
Turbine HR
(Kcal/kWh)
1961-75
1977-82
60 kg/cm2, 482oC
2470
30 – 57.5
70 kg/cm2, 496oC to
2370
60 – 100
90 ata 538oC
130 ata 535/535oC
110 – 120
2170 – 2060
130 ata 535/535oC 210 (Russian)
2060
1983+
150 ata 535/535oC 210 (Siemens)
1984+
170 ata 535/535oC
1990+
150 ata 535/535oC
170 ata 538/538 oC
1951-60
1961-75
Calculated unit
Heat Rate
(Kcal/kWh)
2552-2423
2423
2024
2335
500
1950 (TDBFP)
2294
210/ 250
250/ 500
1950 (MDBFP)
1950 (TDBFP)
2294
2294
*Above are best design values – design rates of individual unit varies
based on reference ambient, coal quality, design and supply dates
Heatrate Improvement over the Years
Heat Rate Improvement (%)
14
12
10
8
6
4
2
0
P == 150
P
150ata
ata
MST
537
MST == 537
RHT
537
RHT ==537
P
130ata
ata
P == 130
MST == 537
537
RHT
537
RHT ==537
P = 170 ata
MST = 537
RHT = 537
200 LMZ (1978) 200 KWU (1979) 500 KWU (1982)
P
170ata
ata
P == 170
MST == 537
537
RHT
537
RHT ==537
500 KWU Mod
(1998)
P = 170 ata
MST = 537
RHT = 565
500 High RH
(2006)
P = 247 ata
MST = 537
RHT = 565
660 SC (2004)
P = 247 ata
MST = 565
RHT = 593
660/800 SC
(2008)
Major Initiatives …..
•
Supercritical Units of 660 MW Rating under construction
•
Supercritical Units of 800 MW Rating with higher steam
temperature conditions under consideration
Parameter
Main Steam Pressure
Kg/cm2
Main Steam
Temperature oC
Reheat Temperature oC
660MW
800MW
247
247
535/565
565
565/593
593
Initiatives for Energy Efficiency
1) Introduction of Supercritical Technology
•
Ultra mega power projects (UMPP) of about 4000MW capacity each
2) Renovation & Modernization of old thermal power
stations
3) Retirement of older small size units
4) Incentive awards for Efficiency improvement
5) Improvement in Performance Parameter Monitoring
6) Comprehensive Energy Audits
7) Setting-Up of Norms for Energy Usage
Barriers to Higher Generation Efficiency
•
•
•
•
Emphasis on plant load factor instead of efficient generation.
Degradation of equipment resulting in loss of capacity.
Delayed overhauls (Seasonal Constraints)
Financial and procedural constraints lead
to inadequate
maintenance ( more importance to financial consideration
rather than technical requirements)
• Lack of awareness on efficiency related issues:
 Inadequate MIS systems (analysis of financial impact of various
operating parameters)
 Inadequate monitoring system for vital operating parameters
 Non availability of performance measuring instruments at station.
 Absence of dedicated group for efficiency improvement
 Poor Operation & Maintenance planning
STEEL SECTOR
Steel Industry – Highlights
Crude steel production was at 54.52 million tonnes, a growth of 1.23%
over last year with capacity utilisation at 89% during the year. It grew
at more than 9% annually from 38.72 million tonnes (MT) in 2003-04.
The growth was driven by capacity expansion from 43.91 million tonnes
per annum (MTPA) in 2003-04 to 64.40 MTPA in 2008-09.
The induction furnace route accounted for 32% of total crude steel
production during 2008-2009.
Steel Industry – Highlights
Steel Industry – Some Energy Fact File !
Major Energy Source
: Coking Coal, Non-Coking Coal, Coke, Electricity
Energy Demand
: Expected about 28% of total industry by 2030
Energy Consumption
: About 35.5 MtoE in 2007-8 (Integrated Steel)
No. of DCs
: 98 as on 2008-09 (with more than 30000 mtoe p.a)
SEC
: 25.5 – 34.2 GJ/tcs (World Benchmark 16.5 – 18.5 GJ/Ton)
Major Energy
Consuming Area
: Coking, Sinter making & Blast Furnace (62%)
Slabbing & Hot Strip Mill (38%)
Source : Energy Guidebook, PCRA
Energy efficiency potential, using best available
technology
5,000
Steel finishing improvements
10.0
4,500
Efficiency power generation from BF gas
9.0
4,000
Switch from OHF to BOF
8.0
Increased BOF gas recovery
7.0
Blast furnace improvements
6.0
COG recovery
5.0
CDQ (or advanced wet quenching)
4.0
7.08
3,500
6.37
3,000
5.40
5.38
2,500
2,000
4.19
3.51
1,500
3.16
Specific savings potential
2.77
2.38
2.20
1,000
2.0
0.99
500
3.0
1.0
0.98
0
0.0
World
China
Ukraine
India
Brazil
Russia
South
Africa
Canada
OECD
Europe
US
Korea
Japan
Other
Saving potential (GJ/t steel)
Energy saving potential (PJ/yr)
9.53
SEC (GJ/tcs) of Main Steel Producers
SPECIFIC ENERGY CONSUMPTION AND ITS TRENDS
SPECIFIC ENERGY CONSUMPTION AND ITS TRENDS
Integrated Steel Plants
Band Width
Upto 2 Million Ton Hot Metal Processing
Between 2 to 5 Million Ton Hot Metal
Processing
Above 5 Million Ton Hot Metal Processing
Range of SPC
(Kwh/ton of Crude Steel)
453 to 580
Based on Last
three Years
418 to 485
Data (details
given below)
400 to 438
Steel Plants based on DRI/ EAF Route
Band Width
1 to 5 Lac TPA
Above 5 Lac TPA
Coverage
(no of Plants
Surveyed)
15
8
Range of SPC
500- 534 Kwh/ton
475- 510 Kwh/ton
Based on Last
three Years Data
Based on Last
three Years Data
Comparison of Specific Energy Consumption
(in million kcal/tonne)
Country
Steel
Cement
Paper
Fertilizer
India
9.50
2.00
11.13
12.23
UK
6.07
1.30
7.62
11.25
USA
6.06
0.95
9.70
11.32
Japan
4.18
1.20
-
-
Sweden
5.02
1.40
7.56
-
Source: Energy Conservation Hand Book, PCRA
Hence, it may be seen that there is a large
‘Bandwidth’ in SEC in all sectors due to one or
more factors.
[In almost every sector, the most energy efficient unit is also
amongst the most efficient units in the world]
This implies that the energy efficiency improvement
targets would have to be
‘UNIT SPECIFIC’
Challenge before the NMEEE
• In order to achieve the target set for the industry in a
sector, the industry has to look for
•
•
•
•
Efficiency improvement in existing plant through retrofit options
Introduce best available technology
R & M of existing plants
Recovery of Waste Energy
It is quite necessary to overcome the barrier (High Initial
Cost) to make the energy efficient technologies as an
attractive option.
Technology Transfer is quite necessary at an affordable cost
and acceptable mechanism.
Thanks ….
For further information, Please Contact
S.P.Garnaik
Joint Director
FICCI, New Delhi
Ph.: 011-23359736
Email: [email protected]
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