Transcript Easter Pastel Eggs - EMT International

Energy Efficiencies
Opportunities for SME’s
… An effective tool to sustain bottom line
Tuesday, April 2, 2013
Energy Scenario
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By 2030, World’s energy needs would be well over 50% higher
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China & India together account for 45% of the increase in global
primary energy demand
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India - one of the fastest growing economies in the world, is poised
to grow at around 7% on moderate term
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India’s energy demand is expected to be more than double by
2030. India will need huge new power generation capacity, which
needs financial & natural resources
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Heavy utilization of depleting conventional energy sources.
Demand supply gap, continuous rise in energy tariffs / rates
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India’s energy intensity is higher, indicates inefficient use of energy
but also substantial scope of energy savings
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What is Energy Efficiency & Conservation (EEC)?
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Energy Efficiency refers using “less energy to provide better or at
least same quality & productivity”
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Energy Conservation refers to “continuous group efforts made to
reduce energy consumption”
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Why EEC?
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Reduction in energy consumption results in energy costs reduction improvement in bottom line
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Reduction in energy costs results in production cost reduction – larger
market share / improvement in top line
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In line with legal framework –
 Energy Conservation Act 2001
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Renewable Energy Purchase Obligation
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Mandatory use of renewable energy (solar & non solar), every year
Perform Achieve & Trade Scheme
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Mandatory conduct of energy audits, once in 3 years
Mandatory reduction in specific energy consumption, every year
Contribution towards improving national energy security, reducing fresh
power generation capacity addition & reducing global worming
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Energy Conservation
 Energy Conservation is not curtailment of energy use.
 Energy Conservation is minimization of wastage of energy
resources.
 Energy Conservation is maximization of productivity of available
energy resources.
 Energy Conservation is increased profitability for the Nation.
 Energy Conservation is also a social obligation.
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Energy Conservation By:
Use of energy efficient practices.
Use of energy efficient technologies.
Reducing wastage – improving efficiency.
Use of alternative sources of energy.
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Energy Saving Potential
 Estimated total conservation potential of the Indian industry is
around 23% of the total energy used by this sector
 Over 5% to 8% saving is possible simply by better housekeeping
and another 10% to 15% with small investment towards low - cost
retrofitting, use of energy-efficiency devices and controls, etc.
 Quantum of saving is much higher if high cost measures like major
retrofitting, process modifications, etc. are considered
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Factors Affecting Fuel Economy
 Following factors affect fuel economy in Industrial Furnace
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Complete combustion with minimum excess air
Proper heat distribution
Maintaining required temperature of the furnace
Reduction of heat losses from furnace opening
Minimizing wall losses
Control of furnace draft
Optimum capacity utilization
Waste heat recovery from furnace flue gases
Sensible heat in flue gas can be salvaged by
 Charge preheating
 Preheating of combustion air
 Utilizing waste heat for other process like generation of steam
or hot water
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Factors Affecting Furnace Performance
 Following factors affect on furnace efficiency:
 Under loading due to poor hearth loading and improper
production scheduling
 Improper designing
 Use of inefficient burners
 Absence of waste heat recovery, instruments and control
 Improper maintenance or operation
 Improper insulation or refractories
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Energy Conservation in Furnace
 Furnaces come in wide variety of configurations and applications.
 Gas and oil are the commonly used as fuel.
 Furnaces efficiencies depend on design,
temperature and
operation. Furnace temperatures vary from 600 0C for tempering
to 1200 0C or more for forging. Higher temperature require higher
gas temperature. Higher exhaust temperature, higher exhaust
losses and low efficiencies.
 Furnace efficiencies can be 10% to 30%. A proper heat balance of
a furnace is necessary to improve operations.
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Energy Conservation in Furnace
 Opportunities:
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Complete combustion with minimum excess air.
Operation at optimum temperature.
Reducing heat losses through opening.
Proper insulation.
Better capacity utilization.
Waste heat recovery.
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Energy Conservation in Furnace (Contd.)
 Minimum Excess Air:
 Proper selection of burners, monitoring of excess air, cold air
ingress control are required.
 Control excess air in furnaces. A 10% drop in excess air amounts
to 1% saving of fuel in furnaces. For an annual consumption of
3000 kl. of furnace oil. This means a saving of Rs 3 Lacs.
 The following table shows the quantum of losses.
Excess Air
Heat loss thru flue gas
25%
48%
50%
55%
75%
63%
100%
71%
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Energy Conservation in Furnace (Contd.)
 Operate at Optimum Temperature:
 Provision of proper temperature control is must. Operator
judgment can be erroneous. Operation at higher temp. Leads to
higher losses and also quality problems.
 Optimum temperature of forging furnace is around 1150 0C
 Minimise Wall Losses:
 Providing proper insulation on all surfaces is a must.
 Use of insulation material having low conductivity, light weight and
hence low thermal mass have dramatically improved efficiencies.
 Can be used for 1200 0C TO 1400 0C.
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Energy Conservation in Furnace (Contd.)
 Waste Gas Heat Recovery:
 Waste gas temperature in furnace are much higher i.e. Approx.
600 0C to 1200 0C
 Preheating of combustion air
 Waste heat can be used for charge preheating.
 For combustion air preheating various type of regenerator,
recuperator are used.
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Energy Conservation in Furnace (Contd.)
 Reduce Losses Through Opening:
 Observations show that a furnace operating at a temperature of
Approx. 1000°C having an open door (1500mm*750mm) results in
a fuel loss of 10 lit/hr. For a 4000 hrs. furnace operation this
translates into a loss of approx. Rs. 4 Lacs per year.
 Proper closing of doors, lids etc. Is must for optimum operation.
Radiation losses are given as follows:
Temperature (0C)
Heat Loss kW/m2
555
25
833
64
1115
161
1400
387
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Thank You