Transcript ENERGY OPTIMIZATION STUDY
ENERGY Conservation Consultancy
By Ravindra M Datar
Senergy Consultants (P) Ltd
www.senergy.co.in
91-22-55993086
Why Conserve?
Product need to be internationally competitive. Cost raises but selling price stagnates. Savings is surest way to increase profits. 10-25% saving can be realized in many industries; half of which with small investment. The nation gains as A new captive power plant take 4 years to construct; while benefits of savings can be enjoyed in 6 months. The power plant costs Rs 50,000/- per kW, while savings costs are not even Rs 10,000/- per kW.
Senergy
Synergy between Our expertise on conservation of energy & Your experience & knowledge of process, operations, plant engineering, etc. To Save Energy
Senergy is
• • • • • • • An ISO 9001-2000 company. In this field for more than 14 years.
Team of experts headed by a technocrat from IIT - Mumbai. A company with customer Base of 300 industries.
Customer driven company with many repeat orders & orders form group companies.
Approved by MEDA & GEDA.
Contributing Rs 50 crores/year, towards conservation of energy.
Senergy
• • • • • • Provides Personalised services. Conducts comprehensive & interactive studies.
Gives practical & realistic recommendations.
Provides services till actual realization of saving. Can organize subsidies and soft loans.
Take responsibility for turnkey implementation, on specific requests.
Few of our clients
• • • • • • • • • • • Century Enka Ltd Century Rayon Nanavati Hospital Essel World EBG India Pvt Ltd JBF Industries Ltd Emco Ltd PepsiCo India Ltd ICI Ltd Essel Propack Ltd M S E B • • • • • • • • • • • Hindustan Lever Ltd Nicolas Piramal India Ltd Wyeth Lederle Ltd Nirlon Ltd GTC Industries Ltd Advani Oerlikon Ltd Frigerio Conserva Allana Ltd Whirlpool of India Ltd Pidilite Industries Ltd Sumaira Group (Tanzania) Ceylon Glass Company Ltd
Senergy: Activities
• Energy Conservation Consultancy. • Promotion of Renewable Energy Sources.
• Turnkey consultancy for non-standard suggestions.
• Consultancy for Process Audit & Yield Improvement. • Consultancy for Proficient Plant Operations.
Road Map: Energy Conservation Consultancy
1.
2.
3.
4.
5.
6.
7.
8.
Team formation Overview of Process & Operations Analysis of Specific Energy Consumption Energy Accounting & Balancing Energy Consumers / Converters Distribution Systems Utilization systems Identification of potential saving areas 9.
Implementation 10.
Monitoring
TEAM
• • • • • • • • • Participation of all concerned.
Positive suggestions through various schemes. Immediate & correct evaluation of suggestions.
Positive solutions for roadblocks / problem areas.
Wider acceptance for recommendation.
Quick and effective implementation. Development of knowledge bank. Continual improvements. Savings on sustainable basis.
Overview of Process / Operations
• • • • Brief description of activities, with emphasis of major consumers. Process / Material flow diagram. Utilization pattern for major consumers.
Co-relate the critical parameters at the point of generation & utilization – Air pressure at compressor outlet / point of utilization – Suction pressure of refrigeration compressor / process temperature
Specific Energy Consumption
Specific energy is the energy consumed per unit output. Analyze variations with respect to – Output – Seasonal variations – Yield Start the analysis at Macro-level then Proceed towards Micro-level
28 26 30 34 32
Example
Specific Energy Consumption
Initial Stage Final Ideal 24 22 20 1000 1050 1100 1150 1200 1250 Production (kg/day) 1300 1350 1400
Energy Accounting / Balance
Prepare break up of consumption for each form of energy by – Measuring energy consumption of individual equipment.
– Noting down operating period.
– Take data from various sub-meters Compare total consumption as estimated above with actual consumption to ascertain – “Unaccounted” or “Miscellaneous” portion of the consumption Analyze consumption pattern (wrt time)
Example
Energy Accounting / Balancing
Description
Illumination Air conditioning Computers Pumps Electrical Heating Residential & Commercial Miscellaneous Total
%
30% 20% 7.5% 12.5% 2.5% 15% 12.5% 100%
kWh/M
5,40,000 3,60,000 1,35,000 2,25,000 45,000 2,70,000 2,25,000 18,00,000
Energy Accounting
Description
Residential & Commercial Hostels Pumping Common Lighting Departments Total
Consumption kWh %
270000 420000 15.0% 23.3% 225000 120000 765000 12.5% 6.7% 42.5% 1800000 100.0%
Average Power (kW)
Month
Aug-04 Sep-04 Oct-04 Nov-04 Dec-04 Jan-05 Feb-05 Mar-05 Apr-05 May-05
Overall
2525 2545 2591 2390 2092 2204 2152 2693 2855 2704
22 to 6
2096 2111 2177 2016 1706 1825 1772 2144 2416 2308
6 to 9 & 12 to 18
2658 2687 2690 2472 2194 2287 2265 2851 3001 2843
9 to 12
2979 2930 2962 2732 2500 2519 2479 3116 3308 3190
18 to 22
2746 2807 2918 2700 2329 2539 2414 2950 3061 2821
Energy Consumers / Converters
Evaluate performance of major consumers to – Carry out energy balance for the entire system.
– Check if the equipment operates at design capacity.
– Estimate efficiency at design / operating capacity.
– Compute specific energy consumption.
– List the major losses and estimate their contribution. – Discuss & finalize ways to eliminate / minimize the losses and optimize the efficiency /output.
– Evaluate possibility of enhancing useful output.
– Check feasibility of using cheaper source of energy do the same work.
Basic Definitions
Efficiency: Ratio of Energy utilized for useful work to the total energy supplied to the equipment. Ratio of to energy supplied less sum of all losses to the total energy supplied to the equipment. Capacity utilization: Ratio of the Actual output to the Rated output of the equipment.
Specific energy consumption: Ratio of the total energy supplied to the equipment to the Actual output.
Specific Power Consumption – Shaft Power (kWh/TR)
Condenser Temperature ( O C) Evaporator Temp ( 0 C)
10 5 0 -5 -10 -15 -20 -25 -30 20 0.27
0.33
0.41
0.50
0.60
0.73
0.87
1.04
1.23
25 0.33
0.40
0.49
0.59
0.70
0.84
1.00
1.18
1.39
30 0.40
0.48
0.57
0.69
0.82
0.97
1.14
1.33
1.57
35 0.47
0.57
0.67
0.80
0.94
1.10
1.29
1.51
1.78
40 0.55
0.67
0.78
0.91
1.07
1.25
1.46
1.72
2.03
45 0.65
0.79
0.89
1.04
1.21
1.42
1.67
1.96
2.31
Refrigeration Effect (TR)
Evaporator Temp ( 0 C)
-10 -15 -20 -25 -30 10 5 0 -5 20 100.0
83.1
68.4
55.9
45.0
35.7
27.8
21.1
15.5
Condenser Temperature ( O C)
25 96.8
80.4
66.1
53.8
43.1
34.0
26.2
19.7
14.4
30 93.7
77.7
63.6
51.6
41.1
32.2
24.6
18.4
13.5
35 90.5
74.8
61.1
49.3
39.1
30.3
23.1
17.4
12.7
40 87.3
71.9
58.4
46.9
36.9
28.6
21.8
16.4
12.0
45 83.9
68.9
55.7
44.4
34.9
27.1
20.7
15.5
11.4
Pr Bar
1 2 3 4 7 10 15
Air Compressor
Sp Power kW/M 3
0.037
0.057
0.077
0.086
0.108
0.128
0.154
Sp Output M 3 /kW
27.0
17.6
13.0
11.7
9.3
7.8
6.5
Power kW
100 153.3
207.3
231.6
291.6
345.6
416.9
Distribution Systems
• • • • • Utilities like steam are generated at centralized place & distributed through out plant.
Such distribution is always associated with drop in energy level.
Distribution losses are such losses expressed as fraction (or percent) of the initial energy.
Such losses can be in in more than one form like pressure drop, heat gain, leakages, etc.
Minimizing such losses is one of the simplest & surest way of conservation of energy.
Example
Distribution Systems
Steam
• • • • Insulation Leakages Pressure drop – Routing – Line size Trapping – Location – Size – Type
Utilization Systems
• • • • • • • Efficient utilization of utilities / energy is of prime importance.
Conduct energy balance for each form of energy.
Identify critical parameters for utilities.
Validate criticality of process / plant parameters.
Map process / plant requirement with generation for critical parameters.
Quantify waste streams and potential for energy recovery through the same.
Look for more economical source of energy.
Energy Recovery from Effluent Chilled Water Ch Water 11 0 C
Process
Waste Ice 8.5 TPD Effluent 12 0 C Fresh Water 30 0 C 221m 3 /day
Plate Type Heat Exchanger
25 0 C E T P 221m 3 /day Chilled Water System 1250 TR / 221 M 3 /day 13 0 C
Identification
of
Energy Saving Areas
• • • • • • Analyze the deviations from norms / normal values.
Identify reasons.
Work out corrective action.
Discuss with TEAM to formulate Action Plan Make simple but complete fact sheet for each area.
Categorize areas based on ease of implementation, investment, etc.
Implementation
• • • Pick up low hanging fruits – it goes in a great way to boost up team moral and management support.
Supervise actual implementation Provide assistance during commissioning & trouble-shooting.
Monitoring
• • • • • Ensure that the Team is on the right path and at correct pace.
Measure the actual savings and ensure realization on sustainable basis.
Devise monitoring system for key energy consumers & prepare log / data sheets.
Install mechanism for suggestion scheme with effective implementation.
Monitor specific energy consumption at macro as well as micro level.
In Nutshell
1.
2.
3.
4.
5.
6.
7.
8.
Team formation Overview of Process & Operations Analysis of Specific Energy Consumption Energy Accounting & Balancing Energy Consumers / Converters Distribution Systems Utilization systems Identification of potential saving areas 9.
Implementation 10.
Monitoring