Energy Efficiency-from a process perspective

Presentation at BEE Workshop for Textile sector at Madurai on 20th November 2010
By S Kannan, Certified Energy Auditor Director -AMSET Energy Systems and Solutions Private Limited, Trichy

Presentation structure
Energy Laws/Basics Energy costs/prices Energy-Process Energy in Textile sector Energy Audits Future Energy About AMSET Back to Basics

Energy Law/Basics
I Law- Law of Conservation Energy can be neither created nor destroyed. It can be transformed from one form into another form. Total quantity of energy in the universe remains constant

II Law (Entropy-Law of degradation) The quality of this energy is degraded irreversibly Entropy is a measure of disorder or uncertainty about a system
Sum total of Energy in the universe is constant, ever was, always will be, moving into form, through form and out of form.

Basic definitions
Energy conservation: Reduction of Energy consumption in physical terms
Energy efficiency: Reduction of Energy intensity in a specific product, process, area of production or consumption, without affecting output, consumption or comfort levels Energy efficiency contributes to Energy conservation

True excellence comes from Knowledge, continuing Education and consistent Practice

Energy costs-India
Type Installation cost-Rs Crore/MW 3.5 to 4.0
1.8 to 2.5

Generation cost-Rs/kw.hr 1.2 to 2.5

0.5-1.0

Thermal
Hydel

Wind
Solar

5.0 to 6.0
22.0 to 30.0

2.8 to 3.8
14.0 to 18.0

Energy prices- India

Agriculture free Domestic-homes- Rs 1.00 to Rs 2.00/kw.hr Industries- Rs 3.00 to Rs 6.00/kw.hr Commercial sector- Rs 5.00 to Rs 7.00/kw.hr Cost of Diesel generation-3 to 3.5 units/lit =Rs 13-15/kw.hr

Aggregate Technical & Commercial [AT & C] losses is between 15% to 50% varying across states of India.

Process
Input Process Output Production is a process Material Management is a process Marketing is a process Ultimately Business is a process!! But the ENERGY process of any Business IMPACTS other key Performance indicators of Business

Energy process parameter

Y = f(X) Output (Product/Services)= f (M,P,E,..) M- Material (Material cost) P-People (Wages) E-Energy (Bill-Fuel + Power)
Efficiency= Output/Input A Mass balance & Energy balance performed on processes, will establish the relationship between the above key variables

Components of material balance Components of Mass Balance

Raw Raw

materials Materials
Chemicals Chemicals

Gaseous Gaseous Emission Emission

Product Product

Water/Air Water/Air

Process or Unit Operation

By By product Product

Waste water Wastewater Liquid waste Liquid waste for For storage storage and disposal And disposal

Energy/power Energy/Power Recycle Recycle Reusable waste Reusable in other Waste in operation

Other operation

Solid waste Solid waste for storage For storage and and disposal

disposal

Components of Energy Balance Components of Energy Balance

Electricity

Energy in Vapours

Energy in vapours

Steam Steam Cooling Cooling Water Water

Radiation loss Radiationloss

Process or Unit Operation

Energy in Energy in hot hot poducts Products

Energy in hot hot Energy in Residues residue Energy in condensate

ChilledWater Chilled water Compressed Compressed Air Air

Energy in Raw Energy in Raw Material material

Energy in Condensate

Energy Energy in in cooling water Cooling water

When it is acute, it is disease When it is chronic, it is nature

PDCA in Energy Management

PDCA-Plan, Do , Check & Act Originally it was PDSA, the S denoting Study, which was replaced with C for Check. The Plan & Check fit into theories while Do & Act fit into application rendering a balanced approach. PDCA is simple and effective, but need to be practiced meticulously on all processes which add value to business. Energy being a major cost parameter in Business, is a good candidate for practicing PDCA

Energy saved= Earned profits

S P E C I F I C O U T P U T

AD- SPECIFIC CONSUMPTION AB- SPECIFIC CONSUMPTION OF PRESENT SYSTEM AC-ACTUAL ENERGY INPUT
ECO- ENERGY CONSERVATION OPPERTUNITY

BC- WASTAGE

EFFORT

ECO

INTEGRATED MANAGEMENT

CRITICAL ASPECTS OF QUALITY,ENVT,OHS &EC

Input Raw Materials Intermediates

PROCESS

PROCESS

PROCESS

OUTPUT

PRODUCTS

ENERGY Analysis For Energy Conservation opportunities

Environmental Aspects Environmental (Env Effects) Stakeholders Government

Hazards
QUALITY

Working Conditions

CHARACTERISTICS
PRODUCT QUALITY

Employees
CUSTOMER

PROFIT

PLANET

PEOPLE

ENERGY RHYTHM

Textile Sector-Overview
Textile Industry- Identified as Energy Intensive industry under Energy Conservation act 2001- > 3000 MTOE/annum Energy Intensity-10.4% of Total Industrial Energy consumption 12-15% of manufacturing cost is Energycomprising Thermal & Electrical energy Energy saving potential > 15% > 600 MW More than 60% of Designated consumers in Tamilnadu are Textile units [> 3000 MTOE/annum

Electricity Consumption in a Composite Mill

Lighting 4% Wet Process 10%

Others 8%

Spinning Preparatory 13% Ring Frame 28% Weaving Preparatory 5%

Humidification 19%

Weaving 13%

Heat Energy Consumption in a Composite Mill

Steam Distribution Network 10%

Bleaching & Finishing 35%

Boiler Plant 25% Humidification & Others 15% Dyeing & printing 15%

Specific Electricity Consumption in Textile Mills

Mill Type & Range Kwh/ Kg

Spinning Mills
Maximum 6.60 Minimum 2.58 Average 4.63

Composite Mills
Maximum 19.50
Minimum 6.70 Average 13.10

Energy saving measures in textile Industries

Installing high efficiency Atomizer in lieu of Nozzles in humidification plants, which result in substantial energy savings Installing energy efficient fans/Blowers in Ring frames, by which a 20% reduction in Power consumption is achieved. Installing VFD for Humidification fans , which will result in annual saving in the tune of 25-30% Convert V-belt drives to synthetic flat belt drives for the TFO machines, as result of this, the annual saving will be 4% per machine. Installing VFD for Autocore suction motor. By this, 15-20 % energy can be saved. Preheating of Boiler feed water by Solar Thermal, resulting in Fuel savings Contd..

Energy saving measures in textile Industries-contd..

Installing VFD for water circulating pumps of jet dyeing machine, which will result in 35 % energy saving. Reducing the speed of Exhaust fans in stenters by using VFD, by which a 40% savings can be achieved GENERAL Measures Replacing old motors with Energy efficient motors Avoiding idle operation of motors Installing waste heat recovery systems, wherever possible. Reducing Transformer & Cabling losses Phasing out of old lights and switch over to Energy Efficient lights Energy conservation in office/administrative buildings-

Energy Audits..
As per Energy Conservation act 2001, Energy Audit is defined as the verification, monitoring and analysis of use of Energy including submission of Technical report containing recommendations for improving Energy efficiency with cost benefit analysis and action plan to reduce Energy consumption.

Energy use-Areas
Thermal Energy systems Boilers, Steam systems, Furnaces, Heat Exchangers, Insulation and Refractory, Co-generation, Waste Heat Recovery
Electrical Energy systems Motors, Pumps, Compressors, HVAC, Fans & Blowers, DG system, Lighting, Transformer, Cabling

Efficiency options
Reduction of Specific Energy Consumption per unit of Production/Service Loss minimization Waste Minimization Low cost Energy substitution Renewable application Process savings- Raw Material & Wages reduction Investment in Energy efficiency is estimated around Rs 1 cr/MW while for a Power producing plant in > Rs 4 Crores/MW + Generation cost!! 1 kwh saved mitigates 1 kg of Co2.

The man who waits for conditions to improve may have to wait for eternity

Approach to Energy Audit

Energy Audit scope-typicalEnergy AuditScope.doc Energy Data questionnaire-Thermal Energy Data questionnaireElectricalEnergy_Audit-Data sheet.doc Target Energy

Instrument List for Energy Audit-Typical

THERMAL
No .
1

Instrument
Flue Gas Analysers Temperature Indicators Infrared Thermometers Thermal Insulation scanner Steam Trap Monitor

Intended Use
Used for optimizing the combustion efficiency by measuring/monitoring the oxygen and CO levels in flue gas of boilers, furnaces etc. and calculation of CO2 percentage in excess air level and efficiency. Used for measuring temperatures of gases/air, iquids, slurries, semi solids, powders etc. Using different types of probes. Used for measuring temperatures from a distance using infrared technology. Used for measuring loss of energy in Kcal per unit area from hot/cold insulated surfaces. The total loss can be obtained by multiplying the total surface under study. Used for performance evaluation of steam Traps.

5 6 7 8 9 10 11 12 13

Conductivity Meter
pH meter Thermohygrometer

Used for on the spot water analysis of the amount of dissolved solids in water.
Used for on the spot analysis of effective acidity or alkalinity of a solution/water. Acidity /alkalinity water. Used for measurement of air velocity & humidification, ventilation, Airconditioning and refrigeration systems etc.

Ultrasonic Flow Meter

U-Tube Manometer Digital Manometer Visguage Used Lube Oil Test Kit

Used for measurement of flow of liquids through pipelines of various sizes through ultrasonic sensors mounted on the pipelines.
Used for measurement of differential pressure. Used for measurement of differential pressure. Used for measurement of differential viscosity. Used for testing lube oil.

ELECTRICAL
1

Non-Contact Tachometer Demand Analyser Power Analyser

Used for measurement of speed of rotation equipment.

Used for measurement and analysis of electrical load and demand control. Used for measurement and analysis of electrical Power.

Harmonic Analyser
Luxmeter Clip on Dig. Watt Meter Clip on Dig. PF Meter

Used for analysis of harmonics in power System.

Used for measurement of illumination level. Used for measurement of power without interrupting the connections.

Used for measurement of power factor without interrupting the connection.

Clamp on amp. Meter Digital Multimeter Frequency Meter Earth Leakage Tester

Used for measurement of current without Interrupting the connections. Used for measurement of voltage. Current and resistance. Used for measurement of power supply frequency. Used for the leakage current in the earthing.

9 10

11

One never notices what has been done; one can only see what remains to be done

Future Energy
The best is the enemy of the good

Reserves Background-Oil/Gas
Oil/Gas- With all information pollution from media about exhaustion, the fact remains that the exact amount of oil/gas reserves is not explored/published!! Opinion of world running out of oil range from year Year 2030 to 2083 to 2100. We may NOT be alive beyond Year 2100 to verify this !! Cost of oil drilling is around $ 15/barrel, while the price is quoting around $ 80/barrel. Even at $ 80/barrel [=165 litres], adding the cost of refining, the cost of oil [petrol/diesel] works out to Rs 25/litre, while it is being sold at > Rs 45/litre average.Almost Govt. receives > Rs 20/litre of oil sold, by means of Taxes and Duties.

Reserves Background-Coal
Under current Reserve to Production ratio, India Coal reserves are estimated to last > 200 years. Many areas in the states of Chattisgarh/MP/Bihar/Jharkhand/Orissa which have Coal reserves, are in areas reserved as forests. Mining coal from forest will call for felling of trees, which will impact the monsoon rains, again a key factor affecting the livelihood of Indian population. Also the quality of Indian Coal is poor compared to that of Australia/Indonesia, containing around 40% ash, which does not give energy and have disposal problems. Coal based power plants pollutes the environment and a recent study of IIM-A has estimated the health cost as Rs 3/kw.hr, which is more than generation cost!! Most polluted city of India is NOT Delhi or Mumbai or Bangalore or Chennai. It is Raipur in Chattisgarh, owing to large scale Coal mining!!.

Energy Future trends-Supply side

Share of Renewable will increase in the Energy mix. Generation cost of Solar is expected to come down drastically by/before Circa 2015. More mini Hydel plants will get installed. Rural energy-Micro turbines/Biomass Share of Gas will increase, as many gas finds are reported-Reliance/Cairn.. Reduction in AT & C losses. Many Electricity boards are mandated.

Energy-Future trends-Demand side

As happened in Telecom, consumers will have the option to chose their Energy supplier. Energy pricing will be aggressive like prepaid, post-paid, off-peak etc. Off-grid consumers-islanding Energy Off shore energy-wind/geothermal

In times of drastic change, it is the learners who inherit the future. The learned usually find themselves equipped to live in a world that no longer exists

AMSET Energy Systems & Solutions Private Limited, Trichy team of Energy Auditors/Managers certified by Bureau of Energy Efficiency

AMSET Energy
Agriculture Manufacturing Services
Experiential Transformational Existing Economy

Future contributors

Energy is used everywhere E=mc2

AMSET Energy- vision

Enable Businesses to reduce Energy costs, by involving People, contributing to Profits and better Planet

Range of Services
AMSET offers the following services Awareness program on Energy costs-conservation-efficiency Energy Audits-Preliminary [walk-through] and Investment grade Carbon advisory-foot printing Energy Management- from a Cost management perspective Total Cost Management-Process approach-Energy + Material + Wages- Cost of Energy related to other major costs. Future Energy- evolution of new Energy technologies Excellence in Energy Management-a journey comprising above

The product of a Consultant should be results for clients-NOT reports

Return to Energy Basics

Energy law-I Energy can be neither created nor destroyed. It can be transformed from one form into another form.Total quantity of energy in the universe remains constant
But. Energy can be WASTED

Law II
The quality of this energy is degraded irreversibly Entropy is a measure of disorder or uncertainty about a system Organizations to evolve a robust Energy Management system, with policies and Planning. Energy can be planned and controlled..

Sum total of Energy in the universe is constant, ever was, always will be, moving into form, through form and out of form.

But It comes with a COST

Knowledge is NOT free. Ignorance is expensive

INTEGRATED MANAGEMENT

CRITICAL ASPECTS OF QUALITY,ENVT,OHS &EC

Input Raw Materials Intermediates

PROCESS

PROCESS

PROCESS

OUTPUT

PRODUCTS

ENERGY Analysis For Energy Conservation opportunities

Environmental Aspects Environmental (Env Effects) Stakeholders Government

Hazards
QUALITY

Working Conditions

CHARACTERISTICS
PRODUCT QUALITY

Employees
CUSTOMER

PROFIT

PLANET

PEOPLE

ENERGY RHYTHM

Change is certain, progress is not

Thanks for attention S Kannan +91 96552 41599 AMSET Energy, Trichy www.amsetenergy.in