ENERGY EFFICIENCY Energy Services (P) Ltd. PRACTICES IN VARIOUS SECTORS Background PGS ENERGY SERVICES PVT. LTD established in 1997 as Accredited Energy Audit firm & ESCO for various energy efficiency/conservation projects of Industry, Commercial buildings & MCs. Our areas of expertise includes a broad spectrum of consultancy & Implementation of EC projects. PGSEPL is also registered as Micro Small & Medium Enterprise with NSIC Empanelment : . BEE . UNDP . EESL PAT : Since 2007 . SIDBI . PEDA Cement, Textile, Iron & Steel, Chlor-Alkali, TPP, Pulp & Paper, Fertilizer . HAREDA EAs : BEE|EESL|NESTLE|HAFED|AAI|PEDA|SDAs|HOSPITALS|HOTEL . GEDA 2009 : Successfully Implemented 1st LED Street light project in India Jan Marg, . MEDA Chd & Majitha PB . H.P SDA IGEAs & ESCO : Chandigarh Administration |SDAs| . Odisha SDA RENEWABLE : Solar Projects|Punjab & Haryana Raj Bhawan| Judicial academy . ASDA Chd |Pb. Civil Sectt.| Haryana assembly, U.T – Sectt. Chd. AAI . DRDO . Chandigarh Admin Cement ACC Limited Ambuja Cements ltd, Ropar Textile: Ambuja Cements ltd, Darlaghat Birla Corporation ltd Vardhman Group HeidelbergCements India Ltd Winsome Yarns Ltd. JK cement Works Reliance Industries Limited Chanderia Cement Works Grasim Industries Arvind Ltd. Birla Century Paper & Pulp Ashima Ltd. Spin fab Satia Industries Ltd Ashima Ltd. Denim BILT Papers Ltd Hisar Spinning Mills Bindals Papers Mills Ltd Soma Textiles & Industries Yash Papers Ltd Rainbow Denim Ltd. Ruchira Papers ltd Suzuki Synthetics Pvt. Ltd Dev Priya Products Ltd Suzuki Suitings Ltd. Naini Tissues Ltd Shree Rajasthan Syntax Ltd. Shree Shyam Paper Mills BMD Pvt. Ltd. Fertilizers IFFCO, Gujarat IFFCO, Odisha FACT, Kerela SPIC, Tamil Nadu Madras Fertilizers ltd GSFC, Sikka Iron & Steel GSFC, Vadodara Anjani Steels ltd GNFC, Gujarat Singhal Enterprises ltd Mangalore Chemicals & Fertilizers Ltd. Top Worth Iron & Steel Rashtriya Chemicals Ltd. Crest Steel & Power Paradeep Phosphates ltd SIEL Chemical Complex Tata Chemicals ltd National Fertilizers ltd Thermal Power plant Coromandel International Ltd. Vizag Yamunanagar TPP Coromandel International Ltd. Tamil Nadu Panipat TPP Deepak Fertilizer & Petrochemicals Corpn. Ltd NTPC Ltd. Kanpur Fertilizers & Cement Ltd. Zuari Agro Chemicals ltd Contents 1. Case Study: Pulp & Paper Sector Strategies for EE & ENCON Approaches 2. Case Study: Cement Sector EE with zero investment 3. Case Study: Building EE project ESCO project 4. Case Study: Iron & Steel Sector Optimization Strategies for EE Case Study: PULP & PAPER INDS. Satia Paper Mills, Muktsar (Punjab) Energy Efficiency strategies adopted: Achievements Quantified 1. Modification in Paper machine (press and wire part) 3350 Mtoe a. Steam saved = 9900 tonne (annual) ~ 10% 936 Mtoe b. Fuel saved = 2600 tonne/yr c. Dryness = 3% increase d. Production = 6 tonne/day increase~1980T/yr 1736 Mtoe e. M/c Speed = 50 rpm increase ~ 51% of more Press part modification for enhanced water removal Hydronip, Hydraulic pistons Press Roller Change Contt………. Energy Efficiency strategies adopted: Achievements Quantified 2. Modifications in Vaccum pumps 29.455 mtoe a. Header modifications 100 kW b. Pump/ Motors replacements 345 kW c. Shutting OFF 3 vaccum pumps 8.6 mtoe (usage = 1 pump) 3. Commissioning of H.P Boiler (490°C) a. increase in evaporation ratio = 3.8 to 3.9 t/t b. fuel saved = 3.16 % ~ 4189 tonne/yr Total savings 1508.22 mtoe Case Study: PULP & PAPER INDS. Ruchira Paper Mills ENCON Approach Benefits/ savings 1. Close loop arrangement for bucket elevator Rs. 7.5 lacs energy cost/yr BENEFITS: a. Furnace efficiency improvement 0.14% b. ID Fan load reduction 84 KWH per day c. Steam saved 39 tonne per day d. Manual labour cost cutting Rs. 8000 monthly e. Fuel saved 0.5 tonne per day ENERGY SAVINGS 2.6MTOE Contt……….. ENCON Approach (Year 2016) Benefits/ savings 2. Heat Exchanger (3 no.s) ~ Black liquor Rs. 2.94 crores~year 1 a. Temp recovered 85° C b. RO water temp increase 35 °C c. Steam saved 80 tonne/day d. Total savings 6.96 MTOE Initial and present scenario comparison Energy Consumption before Heat exchanger 1197980 mkcal Energy Consumption after Heat exchanger 1179764 mkcal SAVINGS 18216 mkal Case Study: Cement Sector Ambuja Cement, Ropar (Punjab) Energy Conservation measures Savings Achieved Increase of biomass usage in place of coal (16 % to 40%) 43,461 mtoe a. Optimisation of excess air in boilers (33% to 30%) 3083 mkcal b. Improvisation in CHP, saving in electrical power 984 mkcal f for coal crushing & Grinding c. Sensible heat savings due to lower flyash (3965 tonne ash) 3230 mkcal Installation of sonic soot blower~dislodging ash deposit 30,521 mtoe a. Energy savings 6985.2 mkcal b. Decrease in fuel consumption 2% approx. Contt…. Energy Conservation measures Savings Achieved Bottom Ash draining via bed ash cooling ~ recover 92,020 mtoe sensible heat from hot bed material a. heat loss savings in bottom ash (coal) 133 kcal/kg coal b. heat loss savings in bottom ash (biomass) 45 kcal/kg biomass Improvisation in packing plant/ interlocking in 54747 mtoe bucket elevator Rs. 1.33 crores a. Increase in production 11 MT/hr b. Reduction in electrical power consumption 1663447.26 kWh c. Reduction in running hours 3473 + 2609 Hrs. Improvement = arresting air leakages + stopping the idle running during shift change +extraction blockage cleaned in silo Case Study: Cement Sector Diamond Cement Ltd. HCIL, Damoh Energy Conservation measure adopted Energy Savings 1. Installation of WHR System 1,01,146 mtoe Benefit: a. Recovery of waste heat from 3 kilns 250-300°C Recovered b. Energy Savings 118.80 Mio kWh c. Annual Cost savings Rs. 784 millions Investment Rs. 1890 millions Payback 2.4 years Case Study: Building ESCO Project As part of an initiative to reduce energy cost and consumption, SDA secured the services of PGS Team to perform an energy audit and prepare a detailed project report of Office Building in an effort to develop com prehensive Energy Conservation and Retrofit Measures (ECRMs). P revious & Present Annual Energy Consumption Scenario Previous Present Type Annual Energy consumption (kWh) Type Annual Energy consumption (kWh) T-12 Double Fixture 10108.80 20 W*2 LED Tube Light 3888.00 T-12 Single Fixture 2920.32 20 W LED Tube Light 1123.20 Old Ceiling Fan 2395.00 BEE five Star Rated Ceiling Fan 1530.00 Old 1.5TR Split AC 33364.80 BEE five Star Rated 1.5 TR Split AC 26092.8 Total 48788.92 Total 32634 Case Study: Office Building Energy Savings in terms of MTOE & Avoided Capacity Generation As a result of implementation of the aforementioned ECRMs, the state would be able to avoid a capacity addition (MW) to cater this reduction of load. This is calculated in terms of Avoided Capacity Generation (MW) using the formula given below: • Total Annual Energy Savings : 16,055 kWh • Avoided Capacity Generation for SDA Building (in MW) = 0.0145 MW • MTOE savings = 1.38 Impacts on reduction of Green House Gases (GHGs)- 13.17 Co2 equivalent Case Study: Steel Industry Singhal Entreprises Ltd. Energy Efficiency strategies adopted: Achievements Quantified 1. Reduction of LOI content Rs. 89.84 lakhs Benefits: a. Unburnt Carbon loss reduction in ash 4.97 to 3 % b. Reduction in coal consumption 3 % c. Improvement in boiler efficiency 3-4 % Technology used~air velocity, uniform raw material size 2. Reduction in bends~steam line to header Rs. 84 lakhs a. Reduction in pressure drop 4 kg/cm2 b. Fuel savings 3% Case Study: Steel Industry Anjani Steels Ltd. Optimization techniques for EE Savings Quantised 1. De-staging of Boiler Feed Pump 158400Kwh Rs. 9.5 Lakhs Removing one stage (From 11 to 10 no.) ~ Discharge Pressur 20kWh e reduction by 6 kg/cm2 (90Kg/cm2 to 84Kg/cm2 ) Investment of 1 lac Payback=1 month 2. Rectifying & Repairing the Leakages at SMS Compressor 144000Kwh Rs. 5.04 Lakhs a. Power saving 1 kWh per leakage b. Zero investment Immediate payback Contt… Optimization techniques for EE Savings Quantised 3. Improvement in Economizer & Air Preheater Efficiency by Cleaning the Tubes & Plugging the Rs. 1.497 Crores Leakages a. Heat loss saving due to air ingress b. Coal consumption reduction (3744 tonne) 5 % No investment Payback= Immediate 4. Reducing the Unload Set Point Pressure at 60480kWh Rolling Mill Compressor Rs. 3.62 Lakhs a. Power Savings 12 kWh b. Pressure reduction (8Kg/cm2 to 7.5Kg/cm2) No investment Payback= Immediate Our Clients… .