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Energy Conservation in Industries

We talk about several aspects in our day-to-day life like cost of living going up, inflation rates, sports, in fact even about the stock market at times. However, have you ever given a thought on energy conservation? Energy conservation is definitely not an issue that will take a significant place in our day to day lives; however it is one of the most important topics that need to be discussed. Each one of us uses energy in some form or the other all day long, throughout the year. Almost every small thing we do requires energy right from cooking to transportation to lighting, cooling and even entertainment.

4/20/2013 THAPAR UNIVERSITY Amit Anand

Submitted by: AMIT ANAND (400907031)

Under the Guidance of

Dr. RUDRA RAMESHWAR

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Sl.No,

Topic Abstract Introduction Energy Trends in India Energy conservation option in industries Industry wise discussion CASE STUDY: Thane Municipal Corp. Tip for energy conservation in industry Energy policies in India Role played by TERI 2 2 4 4 5 17 19 22 23 24 27 28 29 30

Page Nos.

1 2 3 4 5 6 7 8 9

10 Energy conservation act 11 CASE STUDY: Petrobras energy conservation programme 12 CASE STUDY: Heat exchanger at Hydros sture oil terminal 13 Conclusion 14 References

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Abstract
The conservation of energy is an essential step we can all take towards overcoming the mounting problems of the worldwide energy crisis and environmental degradation. In particular, developing countries are interested to increase their awareness on the inefficient power generation and energy usage in their countries. However, usually only limited information sources on the rational use of energy are available. The know-how on modern energy saving and conservation technologies should, therefore, be disseminated to governments and industrial managers, as well as to engineers and operators at the plant level in developing countries. It is particularly important that they acquire practical knowledge of the currently available energy conservation technologies and techniques. The rational use of energy calls for a broad application of energy conservation technologies in the various industrial sectors where energy is wasted. Energy Conservation is unquestionably of great importance to all of us, since we rely on energy for everything we do every single day. Energy supplies are limited and, to maintain a good quality of life, we must find ways to use energy wisely. Reducing the amount of energy that we use is a good way to save money, and there are also other benefits to decreasing energy consumption. Embrace energy conservation by making small changes that will lead to a significant difference in our overall energy consumption. Your efforts, combined with those of others who have chosen to make a few small changes too, will benefit your life and the lives of future generations, as well as our environment

INTRODUCTION
The industrial sector is a major energy consuming sector in India and uses about 50% of the total commercial energy in the country. The total industrial energy consumption, including non-

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energy uses grew from 54700 Ktoe in 2004-05 to 74940 Ktoe in 2010-11. In terms of percentage for the same period the percentage increase of GDP was 84.6% compared to a percentage increase of 63.9% in the energy consumed. Of the commercial sources of energy, coal and lignite contribute about 56%, oil and natural gas about 40%, hydroelectric power around 3% and nuclear power 1%. Over 42% of energy sales from utility sector in 2004-05 were to the industrial sector. In addition, the industry produces 10% of total utility generation through captive power plants, most of which is consumed in-hours. In general, Indian industry is highly energy intensive and energy efficiency is well below that of other industrialized countries (Table 1).

Country India U. K. U.S.A. Japan Sweden

Steel 9.50 6.07 6.06 4.18 5.02

Cement 2.00 1.30 95 1.20 1.40

Pulp and Paper 11.13 7.62 9.70 -7.56

Fertilizer 12.23 11.25 11.32 ---

Efforts to promote energy conservation by such industries could lead to substantial reduction in their cost of production, making them more competitive globally. The consumption of electricity per unit of product in these industries is much higher than in developed countries. Part of it reflects the outdated production processes still in existence. Most of the energy intensive plants are based on international technologies developed during the period when energy efficiency was considered a secondary criterion for plant design. Even in the fifth and sixth plans, hardly any capital schemes encouraging energy conservation were formulated. Concern, if any, in this

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direction has remained confined at the conceptual level within the consultancy organizations without making inroads into the industry in a major way.

ENERGY TRENDS IN THE INDIAN INDUSTRY

The section below discusses few of the major energy consuming industries of India with regard to their energy conservation effort and trends shown by the industries.
Table 2: Absolute energy consumption of energy intensive industries

Absolute energy Industry consumption (million G Cal) Fertilizer Sugar Cement Textile Aluminum Mini-steel Paper Chlor-alkali Glass & Ceramics Food processing 112 100 67 52.5 30.1 27 26 20 15 15

Scope of energy conservation in the sector (%) 10 20 + cogeneration 10 20-25 15-20 9 20 15 15 13

Energy cost as Percentage of mfg cost (%) 60 12 40 13 40 25 25 30-35 30 30

ENERGY CONSERVATION OPTION IN INDUSTRIES- BROAD CATEGORIZATION

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INDUSTRY WISE DISCUSSION-: CEMENT:

India is the 4th largest producer of cement in the world after China, Japan and USA. The cement industry is highly energy intensive with energy costs making up as much as 40% of the total cost of manufacturing. This has been one of the reasons for the high responsiveness of the industry to energy conservation. The drop in specific energy consumption has been spectacular (Table3). New cement plants have their energy performance comparable to international best standards.

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The various studies conducted by the CII indicate a potential energy saving of 10% translating into Rs 3,000 million/year with an investment of approximately Rs 6,000 million to achieve the projected energy savings. Cement industry produces particulate emission that has a significant influence on the environment. The energy saving projects in the industry will also have a huge direct benefit on the environment. Table 3: Specific energy consumption 2004-05 Specific electrical energy consumption (units/tone of cement) Specific energy consumption (kcal/kg of dinker) 122 2010-11 114

930

880

Through energy audits, including kiln system performance testing and calculation of mass and heat balances, specific opportunities for improving energy efficiency and lowering CO2 emissions can be identified. A cement manufacturing energy audit should at a minimum address the energy use and recommend potential actions, such as: Lower kiln exit gas losses

install devices to provide better conductive heat transfer from the gases to the materials, e.g., kiln chains

operate at optimal oxygen levels (control combustion air input) optimize burner flame shape and temperature

Anand improve or add additional preheated capacity Lower moisture absorption opportunities for raw meal and fuels: avoiding the need to evaporate adsorbed water Lower dust in exhaust gases by minimizing gas turbulence: dust carries energy away from the kiln where it is captured in dust collectors; the dust is recycled into the raw meal and fed into the kiln where it is reheated Lower clinker discharge temperature, retaining more heat within the pyroprocessing system Lower clinker cooler stack temperature

In terms of new technologies in the cement sector, several technologies are being tested and demonstrated, such as fluidized-bed kilns. Several large-scale fluidized-bed kiln pilots (200 tonnes/day) have been developed since the mid-1990s and have demonstrated significant energy savings. For instance, it is estimated that a full-scale fluidized-bed (3,000 tones/day) system would be as efficient as the most advanced US kiln utilizing a preheater and precalciner, and 37% more efficient than an average US plant. For fluidized-bed systems the required capital costs are about 12% lower than those of a modern cement facility and their operating costs are about 75% of a modern cement facilitys operating costs. However, in comparison with older, fully capitalized kiln-based plants, the fluidized bed systems are relatively expensive so that they are likely to be considered only for future capacity expansion. Another barrier to adoption of fluidized-bed systems is the reluctance to invest in such large capital expenditures, as the systems have been demonstrated only at small-scale facilities.

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Cement plants, given their large-scale industrial thermal energy demand, offer opportunities for co-generation of electricity and/or steam production, particularly if the co-generation system is part of the initial plant design. This could significantly improve the overall energy efficiency of some manufacturing operations. Presently, five cement manufacturing plants produce electricity on-site through co-generation. Moreover, utilization of waste heat in preheater heat exchange systems is usually more energy efficient than the co-generation of electricity with its inherently low conversion efficiency of thermal to electrical energy (typically about 10,481 Joules are required to produce 1 kWh). Although co-generation of steam at a cement plant is possible, cement plants typically require little steam and are located in isolated areas where markets for excess steam generation are often not available.

SUGAR:
India is one of the largest producers of sugar with the industry expected to grow at the rate of) % p.a. It is also one of the most regulated industries in India. The total absolute primary energy consumption in the industry is around 100 million Goals. The energy consumption is high because of the presence of a large number of small inefficient mills, nonincorporation of energy saving devices and inadequate implementation of energy conservation measures. The sugar Industry holds a great potential for cogeneration due to the surplus bagasse produced. This potential which has been identified at 3500 Mw can improve the financial state of the mills and the power situation in the country.

Energy Conservation in the Sugar Industries:

Anand 1. Installation of Thermo-compressors for the use of Low Pressure (LP) Steam

The sugar industry has many processes and systems that use steam both live medium pressure (MP) steam and exhaust steam. Some of the systems that are live steam users can be totally replaced with exhaust steam, while the live steam consumption can be partially replaced with exhaust steam in other cases. One such live-steam user in a sugar mill is the adjoining distillery. A typical distillery requires steam at about 0.7-0.9 kg/cm sq. for the distillation column and about 1.0-1.2 kg/ cm sq. for the ENA column. The exhaust steam pressure of 0.4 kg/ cm sq. available from the sugar mill will not be able to cater to this requirement. Hence, live steam is drawn from the 8 kg/ cm sq. header and dropped to 1.5 kg/ cm sq. through a pressure-reducing valve, for use in the distillery.

Any conservation measures, which can replace/minimize the live MP steam consumption, can result in maximizing cogeneration in a sugar mill. One such method of minimizing the MP steam consumption is by the installation of a thermo-compressor The thermo-compressor, by passing a very small quantity of MP steam, can compress the waste exhaust steam (typically about 0.4 kg/ cm sq.) available in the sugar mill. The resultant LP steam (typically about 1.5 kg/ cm sq.) can be utilized for any process steam requirement, such the distillation column and ENA column in a distillery. This modification can result in minimizing the usage of MP steam consumption, effectively utilize the heat value of exhaust steam and maximize the cogeneration potential. 2. Continuous Vacuum Pan Technology Batch Pans & Continuous Pans

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Vacuum pans are important equipment used in the manufacture of sugar. The concentrated syrup from the evaporator at around 60-65 Brix is further concentrated in these pans. This is a critical process for the production of good quality sugar and involves the removal of water and deposition of sugar molecules on the nuclei. Massecuite boiling is conventionally carried out by batch process in the Indian sugar industry. These pans are characterized by High hydrostatic head requirement. High Massecuite boiling temperature which cause color formation. Loss of fluidity of massecuite, particularly towards the end of the batch cycle. Higher boiling point elevation resulting in lower heat flux for a given steam condition. Very high steam consumption due to the non-uniform times of the loading, unloading and pan washing cycles The need to overcome these shortcomings led to the development of continuous vacuum pans (CVP), which have now been installed in many sugar plants. The technological development of these pans dates back to the 1970s, beginning with modifications in batch pans and adapting them to continuous operations. The design of these continuous systems aims to obtain maximum overall efficiency with complete automation. Experience with continuous pans has shown improved performances compared to batch pans with greater heat and mass transfer rates along with the possibility of using low-pressure vapors. CVP technology for continuous massecuite boiling in the sugar process offer several advantages, the most important being: Very low hydrostatic loads. Improved grain-size quality.

Anand Wide circulation passages. Heat balance optimization.

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TEXTILE:
The India;, textile industry for 20% of the world production and contributes 2530% of the total value of exports from India. The condition of the plants is quite diverse. In some plants there is a total lack of systematic energy management while in some progressive mills efforts in tuning and systematic energy management at the plant level has significantly contributed to overall profitability of the mill. There is a great potential for using solar thermal energy in this sector because of the requirement of large quantities of low grade heat. The energy saving potential using solar energy is 5 to 30%.

Promotion of Energy Conservation Technologies

While the significance of energy conservation awareness is relatively easily understood at home, when a program is introduced into a factory to promote it, its thorough implementation tends to be delayed at an early stage. Therefore, for its actual course of implementation, it is desired to devise company-wide coordinated measures similar to QC activities at factories. Also, in order to promote energy saving measures efficiently, it is found to be effective to separately consider general management techniques for rational use of energy and process-specific techniques to be developed in each specialized technical field.

Improving efficiency of electricity use (1) Lighting

Due to its nature of operations, the share of lighting in electricity use is relatively high. After the switch from tungsten bulbs to fluorescent lamps achieved considerable electricity savings, electricity-saving

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fluorescent lamps have been developed and marketed for further improvements, including those capable of reducing electricity use by several percent for the same level of illumination. In general, the effectiveness of illumination is influenced by various factors, such as the intensity of light source, the reflection coefficient and shape of the reflective fitting (lamp shade), the layout of the room to be illuminated, interior finish, color and the distance from the light source. Therefore, it is important to reexamine whether the light source is utilized in the most efficient way and take electricity saving measures, if necessary, such as reducing the number of lamps in use by switching from global lighting to local lighting as much as possible

(2) Electric motor

The textile industry uses a vast number of relatively small electric motors. Notably, while a conventional machine was driven by a single motor with the generated mechanical power transmitted to various parts of the machine in a collective manner, many modern machines utilize multiple motors with a control board controlling the movement of each motor, which is directly coupled to a machine part to drive it independently from others. This is also a rationalized feature in terms of energy saving. However, regarding the selection of each motor, emphasis has been placed on mechanical performance, resulting in a motor with an excessive capacity. This leaves considerable room for reexamination from a energy conservation point of view.

(3) Electric heating

In the textile industry, electric heating has largely been replaced by other methods (steam, gas heating, or direct or indirect fired heating) for some time in order to achieve cost reductions. However, since electric heating only requires a small initial investment as a result of convenience and simplicity in equipment construction, it is still used for small capacity local heating purposes. Therefore, it is desirable to conduct a comparative investigation into alternative heating methods, such as far-infrared radiation heating, high frequency dielectric heating and microwave heating.

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As is described before, fuels utilized in the textile industry have already gone through a switch-over from coal to oil. More recently, efficient energy use is under investigation, including the revival of coal on the way to a further move from oil to liquefied and city gases, while reflecting various fuel prices. In selecting fuels, those with good flue gas characteristics in addition to high calorific value and ease of combustion are desired, so that air pollution can be prevented as much as possible.

(5) Selection of boiler By and large, boilers used in the Japanese textile industry have experienced a change from Lancastrian- or Scotch-type tubular or smoke tube to water-tube boilers (natural circulation and forced circulation water-tube boilers and once through boilers). As a result, boiler efficiency has improved from the conventional 60s to 70s of percentage points to as high as the 90s. Since high performance boilers are prone to a rapid growth of scales inside their water tubes, feed water management becomes important. Furthermore, these boilers have small amounts of retained water and high evaporation speeds so that many aspects of their operation are automated, including feed water and combustion management.

ELECTRICAL FIELD:
Energy survey conducted by Ministry of Power in 1992 reveled that there is requirement of improvement in energy generation efficiency, improvement in energy transportation (transmission & distribution systems) and enhancing the performance efficiency of use end apparatus. Study of Energy strategies for Future evolved two things - efficient use of energy, energy conservation and use of Renewable Energy. Energy conservation emerges out to be the

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first and least cost option. To generate 1MW power generation cost is Rs 4.5 to 5.25 crores and T& D cost is Rs.2 crores. But cost of saved power is Rs.1Crores/Mw. The important note is time period to set a power plant is 5 years; to set up transmission line 1 year and to plan energy conservation is only 1 month. We have less opportunity for EC in generating area but we can improve the performance efficiency of generators by optimization of load, optimal distribution of load among different units, periodical maintenance and also increasing the capacity by adopting advanced technology using renewable energy sources. In India the power transmission and distribution (T&D) system is a three tire structure comprising of state grids, regional grids and distribution network. To meet the energy demand power system networks are interconnected through INTRA-REGIONAL LINK. The inter-regional power transmission capacity of India at end of 2007 was 14000 MW. T&D system in India is characterized by heavy losses of about 34.54% according to statistics of 200506, as compared to 10-15% in developed countries.
Table 4: Power losses in T&D system can be classified as Technical losses and Commercial losses.

Power losses occurring in T&D sector due to imperfection in technical aspect which indirectly cause loss of investment in this sector, are technical losses. These technical losses are due to inadequate system planning, improper voltage and also due to poor power factor etc.

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Table 4:

ENERGY CONSERVATION TECHNIQUES: Optimization of loading of transformer: By proper Location of Transformer preferably close to the load center, considering other features like centralized control, operational flexibility etc. This will bring down the distribution loss in cables. Maintaining maximum efficiency to occur at 38% loading (as recommended by REC), the overall efficiency of transformer can be increased and its losses can be reduced.

By Improvisation In Design And Material Of Transformer: To reduce load losses in Transformer, use thicker conductors so that resistance of conductor reduces and load loss also reduces. To reduce Core losses use superior quality or improved grades of Cold Rolled Grain Oriented (CRGO) laminations.

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Replacing By Energy Efficient Transformers:

By using energy efficient transformers efficiency improves to 95 % to 97%. By using Amorphous transformers efficiency improves to 97 % to 98.5%. By using Epoxy Resin cast/ Encapsulated Dry type transformer- efficiency improves to 93 % to 97%.

Energy Conservation In Transmission Line:

To reduce line resistance-R solid conductors are replaced by stranded conductors (ACSR or AAC) and by bundled conductors in HT line.

High Voltage Direct Current (HVDC) is used to transmit large amount of power over long distances or for interconnections between asynchronous grids

By transmitting energy at high voltage level reduces the fraction of energy lost due to Joule heating. (V 1/I so I 2 R losses reduces).

As load on system increases terminal voltage decreases. Voltage level can be controlled by using voltage controllers and by using voltage stabilizer

If required reactive power transmitted through transmission lines, it causes more voltage drop in the line.

To control receiving end voltage, reactive power controllers or reactive power compensating equipments such as Static VAR controllers are used.

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The power consumption by the industrial lighting is nearly 2 to 10 % of total power consumption, depending on type of industries. a) Optimum use of natural light: Whenever the orientation of a building permits, day lighting has to be used in combination with electric lighting. The maxim use of sunlight can be get by means of transparent roof sheets, north light roof, etc b) Replacing incandescent lamps by Compact Fluorescent Lamps (CFL's): CFL's are highly suitable for places such as Living rooms, Hotel lounges, Bars, Restaurants, Pathways, Building entrances, Corridors, etc. Table 5:

c) Replacing filament lamps on panels by LED: LED lamps consumes less power (1 W lamp), withstand high voltage fluctuation in the power supply, longer operating life (>100,000 hrs). Hence nowadays they are also used in street lighting, signaling, advertising boards, even as replacement for tube light or CFL.

Case study: Thane Municipal Corporation

Thane Municipal Corporation initiated the project of energy conservation in year 2001 by identifying the area- municipal building, municipal hospital, street lights, pumping station sewage pumping station. The initial energy status was as Municipal Buildings: 2970 kW

Anand Municipal Hospital: 1276 kW Streetlight: 7364 kW Water supply: 6634 kW Sewerage pumping stations: 1299 kW

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Total: 19573 kW (19.5 MW)

Through energy conservation cell awareness program, periodical maintenance program utilization of alternative energy sources, energy generation (methane gas), quality control & use of in-house man power TMC obtained the success in all its energy conservation programs For its efforts TMC received first prize in State Level Award For Excellence In Energy

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Conservation & Management for year 2004 & 2006 First prize in National Energy Conservation Award 2005.

Tips for Energy Conservation in Industrial Sector

GENERAL

Undertake regular energy audits. The maintenance in plant should follow the "Zero Leak" philosophy, particularly in the areas of steam and utilities so that loss of energy could be totally eliminated.

Plug all oil leakage. Leakage of one drop of oil per second amounts to a loss of over 2,000 litres/year.

Filter oil in stages. Impurities in oil affect combustion. Pre-heat the Oil. For proper combustion, oil should be at right viscosity at the burner tip. Provide heat capacity.

Incomplete combustion leads to wastage of fuel. Observe the color of smoke emitted from chimney. Black smoke indicates improper combustion and fuel wastage. White smoke indicates excess air and hence, loss of heat. Hazy brown smoke indicates proper combustion.

Use of low air pressure "film burners" helps save oil up to 15 per cent in furnaces.

FURNACE Recover and utilize waste heat from furnace flue gases for preheating of combustion air. Every 21oC rise in combustion air temperature results in one per cent fuel oil savings.

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Control excess air in furnaces. A 10 per cent drop in excess air amounts to one per cent saving of fuel in furnaces. For an annual consumption of 3,000 kilolitres of furnace oil means a saving of Rs. 3 lakh (assuming the cost of furnace oil is Rs. 10 per litre).

Improve insulation if the surface temperature exceeds 20C above ambient. Studies have revealed that heat loss from a furnace wall 115 mm thick at 650C amounting to 2650 Kcal/m /hr can be cut down to 850 kcal/m/hr by using 65mm thick insulation on the 115 mm wall.

BOILER All possible attention should be paid to control excess air by monitoring oxygen level in flue gas and also by visual inspection of flame color. Use only treated water in boilers. A scale formation of 1mm thickness on the waterside would increase fuel consumption by five per cent to eight per cent Remove soot deposits when flue gas temperature rises 40C above the normal. A coating of 3mm thick soot on the heat transfer surface can cause an increase in fuel consumption of as much as 2.5 per cent

DG SETS A poorly maintained injection pump increases fuel consumption. A faulty nozzle increases fuel consumption. Blocked filters increase fuel consumption. A continuously running DG set can generate 0.5 tonne/hour of steam at 10 bar to 12 bar from the residual heat of the engine exhaust per MW of the generator capacity

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COMPRESSED AIR Compressed air is very energy intensive. Only five per cent of electrical energy is converted to useful energy. Use of compressed air for cleaning is rarely justified. Increase in inlet air temperature by 3C increases power consumption by one percent. Ensure low temperature of inlet air. Reduction in discharge pressure by 10 per cent saves energy consumption up to five per cent. It should be examined whether air at lower pressure can be used in the process.

PUMPS Select a pump of the right capacity in accordance with the irrigation requirement. Improper selection of pump can lead to large wastage of energy. A pump with 85 per cent efficiency at rated flow may have only 65 per cent efficiency at half the flow. It is advisable to use a number of pumps in series and parallel to cope with variations in operating conditions by switching on or off pumps rather than running one large pump with partial load. Use efficient transmission system. Maintain right tension and alignment of transmission belts. Use low friction rigid PVC pipes and foot valves

COOLING TOWERS Replacement of inefficient aluminum or fabricated steel fans with moulded FRP fans with aerofoil designs results in electricity savings in the range of 15 percent to 40 per cent.

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A study on a typical 20 feet diameter fan revealed that replacing the wooden blade drift eliminators with newly developed cellular PVC drift eliminators reduces the drift losses from 0.01 per cent to 0.02 per cent with a fan power energy saving of 10 per cent.

Install automatic ON-OFF switches on cooling tower fans and save up to 40 per cent on electricity costs.

ENERGY POLICY IN INDIA

The energy conservation policy is determined in a manner similar to energy policy. The Ministry of power has been designated as the nodal agency for energy conservation and consequently much of the policy formulation is initiated in the Ministry of Power. However, policy formulations have also been initiated in the Ministry of industry and Ministry of Petroleum. They are generally discussed with the Ministry of Finance and in Inter-Ministerial Committees before being sent to the cabinet for approval. Major Government initiatives towards energy conservation are: a) Depreciation allowance at 100% in the first year on certain energy saving devices and systems. b) Certain energy-efficient equipment are exempt from the payment of excise and / or custom duty, and reduced custom duty is applicable on specified equipment/devices used in the industry. c) Soft loans from financial institutions for technology up gradation and introduction of energy conservation measure. d) Subsidies for consultancy y and training in the areas of energy management and conservation;

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e) Strengthening of Energy Management Centre (EMC) for coordinating information dissemination, and strengthening of National Productivity Council (NPC), TIFAC and other organization.

ROLE PLAYED BY TERI

Tata Energy Research Institute (TERI) is an autonomous, non-for-profit, research institute established in 1974. In the initial period the institute concentrated on documentation and

information dissemination activities. Towards the end of 1982, research activities were initiated in the fields of energy, and expanded soon to cover the environment, biotechnology, forestry and a whole mage of sustainable development issues. TERI is working in close association with the Indian industry for enveloping solutions to the challenges posed by the growing demand of energy on one hand and the growing demand of fuel coupled with increasing prices on the other. It is involved in disseminating knowledge and developing expertise in the energy conservation among industry personnel through the major activities a) Energy audits, b) Technology promotion/demonstration, c) Training/information dissemination. Energy audits: Energy audits can be considered as the first step towards understanding as to how energy is being used in a given facility. It indicates the ways in which different forms of energy are being used and quantifies energy use according to discrete functions. Energy audit does not provide the final answer to the problem but only identifies where the potential for improvement lies and therefore where the efforts of the management should be concentrated upon.

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Technology promotion/demonstration: This involves demonstration projects (presently small scale and refrigeration sectors) and macro-level studies on energy efficient technologies and process. TERI aims at finding solutions to the energy and the environment problems of the SSI through technology up gradation and human and institutional development in some small scale energy intensive sectors. Four small scale sectors are presently being covered foundry, glass, brick and sericulture. Besides demonstration projects awareness programs and training of the entrepreneurs and operators will also be carried out simultaneously to familiarize them with the new technologies. Appropriate mechanism (to support the preparation, financing and

implementation of replicable projects) will be worked out with an effort try and make this program sustainable beyond the project intervention. Training/ information dissemination: Many investors and most of the consumers have insufficient information on the rapidly evolving technologies that are available. Furthermore, they are uncertain regarding the energy saving and cost-efficient designs. By organizing training programs and workshops TERI is disseminating knowledge gained through energy audits Demonstration projects to industry personnel.

THE ENERGY CONSERVATION ACT Considering the vast potential of energy savings and benefits of energy efficiency, the Government of India enacted the Energy Conservation Act, 2001 (52 of 2001). The Act provides for the legal framework, institutional arrangement and a regulatory mechanism at the Central and State level to embark upon energy efficiency drive in the country. Five major provisions of EC

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Act relate to Designated Consumers, Standard and Labeling of Appliances, Energy Conservation Building Codes, Creation of Institutional Set up (BEE) and Establishment of Energy Conservation Fund. The Energy Conservation Act became effective from 1st March, 2002 and Bureau of Energy Efficiency (BEE) operationalized from 1st March, 2002. Energy efficiency institutional practices and programs in India are now mainly being guided through various voluntary and mandatory provisions of the Energy Conservation Act. The EC Act was amended in 2010 and the main amendments of the Act are given below: The Energy Conservation (Amendment) Act, 2010- Main Amendments

The Central Government may issue the energy savings certificate to the designated consumer whose energy consumption is less than the prescribed norms and standards in accordance with the procedure as may be prescribed.

The designated consumer whose energy consumption is more than the prescribed norms and standards shall be entitled to purchase the energy savings certificate to comply with the prescribed norms and standards.

The Central Government may, in consultation with the Bureau, prescribe the value of per metric ton of oil equivalent of energy consumed.

Commercial buildings which are having a connected load of 100 kW or contract demand of 120 kVA and above come under the purview of ECBC under EC Act.

BEE - Scope of Activities

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The Bureau of Energy Efficiency (BEE) was established on 1st March 2002, under the Energy Conservation (EC) Act, 2001. BEE is responsible for spearheading the improvement of energy efficiency in the economy through various regulatory and promotional instruments Plan, manage and implement provisions the EC Act Appliance standards and labeling Industrial energy benchmarks Energy Conservation Building Codes Monitor energy use in high energyconsumption units Certify and accredit energy auditors and energy managers Provide a policy framework and direction to national energy conservation activities Disseminate information and knowledge, and facilitate pilot and demonstration projects Establish EE delivery systems through Public-Private Partnerships (PPP). Responsibilities and Duties of Energy Auditor

Responsibilities and Duties of Energy Auditor Carry out a detailed energy audit Quantify energy consumption and establish base line energy information Construct energy and material balance Perform efficiency evaluation of energy & utility systems Compare energy norms with existing energy consumption levels Identify and prioritization of energy saving measures Analyse technical and financial feasibility of energy saving measures Recommend energy efficient technologies and alternate energy sources Report writing, presentation and follow up for implementation. Responsibilities and Duties of Energy Manager Responsibilities and Duties of Energy Manager Establish an energy conservation cell & prepare an annual activity plan Develop and manage training programme for energy efficiency at operating levels Develop integrated system of energy efficiency and environmental improvement Initiate activities to improve monitoring and process control to reduce energy costs Co-ordinate

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implementation of energy audit/efficiency improvement projects through external agencies Establish / participate in information exchange with other energy managers of the same sector through association Provide information to BEE and Designated Agency of the respective States as demanded in the Act.

CASE STUDY: PETROBRAS ENERGY CONSERVATION PRO GRAMME

Improving energy performance has been a major priority of Petrobras, the majority state-owned Brazilian oil company, since the first oil crisis in the early 1970s, when it first established the Energy Conservation Programme. It involves targets for energy use in each area of the companys activities with the aim of lowering energy consumption and/or reducing spending on fuel. This is achieved by raising awareness of the importance of energy saving among employees, taking energy efficiency into account in preparing technical specifications for new projects, and analyzing and reporting energy consumption levels. The programme consists of a wide variety of activities and projects, including upgrading operating procedures in oil refining processes; optimizing the distribution and use of steam and power generated on site; preventing leaks and spills; and installing heat-recovery boilers and air preheating systems

Although all projects are required to yield a financial return to the company, environmental aspects are always taken into consideration when selecting the projects to be implemented. Petrobras estimates that the programme has saved the company approximately 13 Mtoe of energy over the 32 years of its existenceequal to 11 per cent of all energy consumed by the

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company during that period. Investments under the Programme amount to $210 million (in year2005 dollars). Savings in CO2 emissions are estimated at about 42 million tonnes, while the average amount of CO2 emitted per unit of energy consumed has fallen by around 20 per cent. Despite these achievements, Petrobras has identified significant potential for further energy savings. Several major projects are currently under way, including a range of measures to reduce gas flaring. The company is also planning to install four turbo-expanders at different refineries, with a total capacity of 68 MW. Turbo-expanders use the energy contained in the flue gas emitted by catalytic cracking units, which are found at most Petrobras refineries, to generate electricity.

CASE STUDY: HYDOS STURE OIL TERMINAL

The Hydro-operated Sture oil terminal on the west coast of Norway receives oil through two pipeline systems: The Oseberg Transportation System, which began operating in 1989. It comprises a 115km pipeline that brings crude and condensate from the Oseberg, Brage and Veslefrikk offshore fields. The oil contains some associated gas, which is separated out. The naphtha and liquefied petroleum gases contained in the oil are also removed in a processing plant before the oil is shipped from the terminal. Close to 26 million cubic metres of crude oil and condensate were shipped from the terminal in 2006. The Grane Transportation System, a 212-km pipeline bringing crude oil from the Grane field.The system came onstream in 2005. Grane crude is heavy and must be heated to facilitate loading operations at Sture. Heat requirements amount to 9 MW.

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The processing of the Oseberg oil involves heating it to approximately 100C. A heat exchanger was constructed in 2006 to transfer excess heat from the Oseberg crude after processing to the cold and heavy Grane crude. The heat exchanging process saves approximately 8,000 toe of energy each year, reducing CO2 emissions by about 25,000 tonnes

CONCLUSION
In general, it can be seen- that there is considerable scope for the improvement of energy efficiently in the energy intensive industries. Efforts to promote energy conservation by such industries could lead to substantial reduction in their cost of production, making them competitive globally. As 1 keh saved at the user end could mean a relief of 2-4 kwh of generation capacity depending upon the plant load factor, transmission and distribution losses, and end use efficiency, energy conservation offers the least cost option for bridging the ever widening gap between demand and supply of energy. In order to motivate entrepreneurs to take up energy efficiency drive seriously, many state governments have made energy audit mandatory for units above a certain size (generally related to connected load). But the fact remains that the real motivation will come when the entrepreneurs start realizing the actual benefits of energy use and use it as a tool to increase profits and productivity, rather than view it as a statutory requirement.

Anand

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REFERENCES
1) Maynards Industrial Engineering Handbook Willium K. Hodson. 2) Energy Stimulation in Building Design Jaclar Ke. 3) Renewable Energy from the ocean William H. Avery Chih Wu 4) Renewable Energy N. K. Bansal 5) Cane Cogen India July 2002 6) www.mahaurja.com 7) www.bee idia.nic.in 8) http://climatetechwiki.org/technology/energy-saving-cement 9) White paper on tips to save energy 10) http://www.powermin.nic.in/acts_notification/energy_conservation_act/introduction.htm