Dr. Binoy K Choudhury
Indian Institute of Social Welfare & Business Management (IISWBM)
Conference on
Low Carbon Energy for Development: Past Experiences and Future Challenges
Loughborough University, UK
Low Carbon Energy Use in SMEs and Larger Industrial Establishments : Some Cases From India
SECTORAL SHARE OF COMMERCIAL ENERGY CONSUMPTION IN INDIA (MTOE) (2007-08)
TOTAL = 272.4 MTOE
INDIAN ENERGY USE
Coal, oil and natural gas together account for more than 95% of India’s primary energy supply (excluding biomass), whereas the share of hydro, nuclear, and other renewables is less than 5%.
India – Potential for various Renewable Energy Technologies by 2020
Sources/System Approximate Potential
Biogas plants (in millions) 12
Improved woodstoves in millions) 120
Biomass (MW) 61,000 - 123,000
Solar Energy (MW/kM2 ) 20 (50,000 MW)
Wind Energy (MW) 45,000 (on shore)
Small Hydropower (MW) 10000
Ocean Energy (MW) 50000
Of the total potential of 183,000 MW, installed capacity of grid-interactive & off-grid power by March 2011 was 20492 MW, amounting to only 11.2%
[RE Potential > Overall Total Installed Capacity]
GHG Emissions Distribution (MT CO2-eq) Across Sectors (2007)
TOTAL = 1398.7 CO2 eq
INDIAN ENERGY SAVING POTENTIAL
A recent study by the World Resources Institute (WRI) India’s
energy demand is expected to become more than double by
2030. The country is consequently in need of a huge amount of
new power generation capacity. Considering the figures of the
WRI, the cheapest generating capacity for India will no doubt
be energy savings. The savings potential is estimated to vary
from 20% to 50%.
ENERGY USAGES & LOSSES
Energy LossesEnergy Losses
Causes of Losses– Supply chain Management (handling and storage) – In-efficiency of Conversion
• Technology• Maintenance Practice
– End Use In-efficiency • Lack of New
Technologies• Lack of Energy Modesty
Causes of Losses– Supply chain Management (handling and storage) – In-efficiency of Conversion
• Technology• Maintenance Practice
– End Use In-efficiency • Lack of New
Technologies• Lack of Energy Modesty
Energy LossesEnergy Losses
Energy LossesEnergy Losses
Interdisciplinary Issues• Administration• Policy• Tariff, Cost Control• Alternative Fuel• Renewable• CDM
• Energy Certification
Interdisciplinary Issues• Administration• Policy• Tariff, Cost Control• Alternative Fuel• Renewable• CDM
• Energy Certification
Ministries/Depts Involved
• Planning Commission
• Power
• Petroleum & Nat. Gas
• Coal
• MNRE
• Dept of Atomic Energy
BENEFITS OF ENERGY CONSERVATION
Investment - Only a third compared with Capacity Addition
Low Carbon Option (as Burning of Fuel is not Required)
Savings of Foreign Exchange as India Imports about 34% of the total Energy Resources Used
Social Issues (Earth with Resources are Borrowed from Future Generation)
Environmental Issues (reduces pollutant emissions)
National Energy Security Option
Investment - Only a third compared with Capacity Addition
Low Carbon Option (as Burning of Fuel is not Required)
Savings of Foreign Exchange as India Imports about 34% of the total Energy Resources Used
Social Issues (Earth with Resources are Borrowed from Future Generation)
Environmental Issues (reduces pollutant emissions)
National Energy Security Option
ENERGY CONSERVATION MEASURES
CASE 1 : Supply Chain Management Control - Carpet Loss & Rain Water Protection
•One of the Leading Electricity Supply Company Could Reduce the Maintenance Cost in the CHP by Constructing Rain-water Shed to the Tune of GBP 3 million/year Besides Efficiency Improvement of the System.
•Total Investment was GBP 3 million (One Time) Only.
•Thus the Pay-back Period Is Around One Year.
ENERGY CONSERVATION MEASURES
CASE 2 : (Process) Energy Efficiency - Air Infiltration – Excess Air Issue : At BANDEL THERMAL POWER STATION
T/hr 198.80CN.A HOT RE T/hr 143
Kg/cm2 N.A HOT RE 0C497
HOT RE Kg/cm2 19.7
COLD RE T/hr 143
COLD RE 0C380
COLD RE Kg/cm2 24
MS T/hr 196
MS 0C503
MS Kg/cm2 99.5
2nd Ext.T/hr N.A
2nd Ext. 0C170
2nd Ext. Kg/cm2 8.1
1st Ext.T/hr 53
1st Ext.0C380
1st Ext. Kg/cm2 243rd Ext.T/hr N.A
3rd Ext. 0CN.A
3rd Ext. Kg/cm2 2.5
HTR T/hr 198.8
T/hr 198.8 HTR 0C1450C170 HTR Kg/cm2 141.3 4A T/hr 112.8
Kg/cm2 4A 0C145
4A Kg/cm2 151.7
T/hr 198.8 4C T/hr0C215 4C 0C N.W
Kg/cm2 148 4C Kg/cm2 N.W
4B T/hr 86 T/hr 198.8
4B0C145 0C145
4B Kg/cm2 157.3 Kg/cm2 3.9
N.A - NOT AVAILABLE HPT - HIGH PRESSURE TURBINEN.W - NOT WORKING IPT - INTERMEDIATE PRESSURE TURBINEBFP - BOILER FEED PUMP LPT - LOW PRESSURE TURBINEHTR - HEATER CEP - CONDENSATE EXTRACTION PUMP
FIGURE 1A. WATER & STEAM CIRCUIT OF BTPS UNIT # 4 WITH IMPORTANT MASS &ENERGY FLOWS (55MW)
HTR2
HTR1
BFP4B
BFP4A
BFP 4C
BOILER HPT IPT
ECONOMISER
DRUM
WATER AND STEAM CYCLE
GENERATION = 55MW
T/hr N.A DATE = 17.10.060CN.A
Kg/cm2 N.A
T/hr 1340C 46 CW T/hr
Kg/cm2 N.A CW 0C31
CW Kg/cm2
COND T/hr 134
COND 0C46
COND cm Hg 8.0
T/hr
DM T/hr N.A 0C39.75
DM 0C N.A Kg/cm2
DM Kg/cm2 N.A5th Ext.T/hr
5th Ext. 0C 62
0.34CEP T/hr
CEP0C HTR 5 INLET
CEP Kg/cm2 HTR 5 T/hr N.A
HTR 5 0C53.7
HTR 5 Kg/cm2 4.9HTR 4 INLET
4th Ext.T/hr HTR 4 T/hr N.A
4th Ext. 0C HTR 4 0CN.A
4th Ext. Kg/cm2 0.63 Kg/cm2 4.9 DP T/hr N.A
DP 0CN.A
DP Kg/cm2 N.AHTR4HTR 4 T/hr N.A
OUTLET HTR 4 0C N.A
HTR 4 Kg/cm2 4.25
Bypass to Condenser
5th Ext.
Kg/cm2 (abs)
LPT LPT
CONDENCER
CEP
DM PLANT
Deep Tube well & Treated water pump
RIVER WATER
HTR 5
DA
HTR 4
DP
HOT WELL
55MW
AIR & FLUE GAS (FG) PATHGENERATION: 55MWDATE:17.10.06
ECO INLET (FG)
Temp. (0C ) 400.6
O2% 1.9
CO2% 17.0
COAL CO OOR25.4% Ash Flow 259.635.13 T/hr WATER OUT5266 Kcal/ Kg ECO
WATER INECO OUTLET (FG)
Temp. (0C ) 336.1 /APH INLET(FG)
O2% 3.4
APH CO2% 15.9
CO 637.0Flow 278.5
APH INLETAPH OUTLET ESP INLET (FG)/APH OUTLET ESP OUTLET (FG)/ID INLET
Temp.(0C ) 32.4 Temp. (0C ) 282.5 Temp. (0C ) 177.5 Temp. (0C ) 139.4
O2% 21 O2% 20.9 O2% 6.8 O2% 10.735
Flow 226.3 CO2% 0 CO2% 12.8 CO2% 0
CO (ppm) 6.7 CO 7971 CO OORFlow 336.5 Flow 446.5
Note: Assumtions: Air :Coal (Stoiciometric) = 5.8
OOR Out Of Range Excess Air= O2X100%/(21-O2)
Acuracy Upto 1st decimal place Fly Ash in Total Ash = 80%
ESPID
FD
Generation 55 MWDate: 17.10.06
Power Loss in ID Fan due to Infiltration of Air/Gas
Coal Burning Rate 35.13 T/HrStoichiometric Air Coal Ratio 6Stoichiometric Air 205.44 T/HrExcess Air Allowable for Complete Combustion= 21.00% of Stoi.AirExcess Air Allowable to Consider Infiltration in Economiser and APH, as per design= 2.00% of Stoi.AirExcess Air Allowed in ESP (assumed) 2.00% of Stoi.AirDesirable Flue Gas Flow at ESP Outlet, as per design 283.01 of Stoi.AirExcess of Excess Air (Actual - Desirable)= 163.49 T/HrReduction in Flow, if there were no excess of excess air= 36.62%Reduction in Consumption of Power (Ref. BEE Book 3, p98)= 15.63%Actual Power Consumption in ID Motor = 779 kWSaving in ID Fan Power, if there were no excess of excess air= 121.72 kWPlant Operating Hours = 3200 Hrs/AnnumElectrical Energy Saving = 389,500 kWh/AnnumBTPS Electricity cost (Rs/kWH) 0.022 GBP/kWhAnnual Monetary Saving = 8,466GBP/AnnumResulting Reduction in Plant Auxiliary Consumption = 2.21%
EXECUTIVE SUMMARY – BTPS UNIT # 4 & COMMON AREAS
Sl No
Energy Conservation Opportunities Recommended for Implementation
Estima-ted Annual Savings (GBP)
Proba-ble Inves-tment (GBP)
Simple Payb-ack (mon-ths)
Estimated Life of the Proposed System (Yrs)
Depreciation Charge (GBP/yr)
ROI (%)
Reduction in Aux. Cons(%)
Reduction in Heat Rate (%)
1 Limit the infiltration of atmospheric air to design value and associated thermal benefits 367,584 5,681 0.2 6 947 6454 1.33% 7.12%
2 Use of HF Electronic Ballast in pace of tube lights and associated electrical benefits 20,242 30,807 18.3 9 3081 56 2.03%
TOTAL 387,826 36,488 1.13 3.36% 7.12%
TOTAL CO2 REDUCTION BY ABOVE = 18765 Ton/Year
ENERGY CONSERVATION MEASURES
CASE 3 End Use : Power Generation Potential From Blast Furnace Gas
BLAST FURNACE AREA•Recovery of B.F. Gas•Improved Automation of Hot Blast Stove•Utilities- Pumps, Fans, Compressor, Conveying Systemsand Cooling Towers - Energy efficiency improvements
Sinter,Pellet, Ore, Flux, Coke
BF flow sheet
CASE STUDY : IRON & STEEL INDUSTRY (300 Mta)
Estimated CO-GENERATION FROMFLARED BF GAS:
• Savings per annum GBP 6.43 million
• Estimated investments GBP 11 million
• Simple pay back 21 months
• ROI – 52.27%
CASE 4 : ENERGY EFFICIENCY MEASURESAt Howrah Galvanizing and Wire Drawing Industries
Definition of MSMEs in IndiaDescription Investment in (GBP)
in Plant & MachineryInvestment in (GBP)
in Equipment
Manufacturing Enterprise
Service Enterprise
Micro Enterprises upto 30,750 upto 12,300
Small Enterprisesabove 30,750 & upto 615,000
above 12,300 & upto 246,000
Medium Enterprises
above 615,000 & upto 1.23 million
above 246,00 & upto 616,000
Large Enterprises above 1.23 million above 616,000
Profile of Indian SME SectorSl No Particular Value
1 Number of micro and small enterprises
13 million
2 Employment 41 million
3 Share in GDP 8-9%
4 Share in manufacturing output 45%
5 Share in exports 40%
List of BEE SME Energy Efficiency Programme Clusters
Sl. No.
Phase Sector Name Cluster Name State
1 1 Chemicals Ahmedabad Gujarat
2 1 Rice milling Warangal Maharashtra
3 1 Brass Jamnagar Gujarat
4 1 Textiles Solapur Maharashtra
5 1 Textiles Surat Gujarat
6 1 Textiles Pali Rajasthan
Contd ..
7 1 Ceramics Morbi Gujrat
8 2 Oil Mills Alwar Rajasthan
9 2 Machine tools Bangalore Karnataka
10 2 Foundries Batala, Jalandhar and Ludiana
Punjab
11 2 Ice making Bhimavaram Andhra Pradesh
12 2 Brass Bhubaneswar Orissa
13 2 Refractories E and W Godavari
Andhra Pradesh
Contd ..
14 2 Rice milling Ganjam Orissa
15 2 Dairy Gujarat Gujarat
16 2 Galvanizing and wire drawing
Howrah West Bengal
17 2 Brass and Aluminium utensils
Jagadhri Haryana
18 2 Lime kilns Jodhpur Rajasthan
19 2 Tea Jorhat Assam
20 2 Sea food processing
Kochi Kerala
21 2 Paper Muzaffarnagar Uttar Pradesh
22 2 Sponge Iron Orissa Orissa
Contd ..
23 2 Chemicals Vapi Gujarat
24 2 Bricks Varanasi Uttar Pradesh
25 2 Rice milling Vellore Tamil Nadu
26 3 Coir Alleppey Kerala
27 3 Tile Mangalore Karnataka
28 3 Textile Tiripur Tamil Nadu
29 3 Glass Firozabad Uttar Pradesh
Process flow diagram after project implementation :Air Pre-heater for Galvanizing and Annealing Furnaces
TECHNOLOGY : ENERGY EFFICIENCY MEASURESInstallation Of Air Pre-heater
TECHNOLOGY : ENERGY EFFICIENCY MEASURES
Case study : Installation Of Air Pre-heater In Howrah Galvanizing And Wire Drawing Industries
S.No Particular Unit Value
1 Project cost GBP 3,0782 Furnace Oil saving litre/year 53073 Monetary benefit GBP 2,2254 Debit equity ratio Ratio 2.445 Simple payback period Year 1.386 NPV GBP 3,2637 IRR %age 528 ROI %age 35.429 DSCR Ratio 2.7810 CO2 emission reduction Ton/year 1611 Process down time Days 4
Case study : Using Biomass Gasifier instead of Furnace Oil/Coalin Galvanizing of Howrah Cluster
Sl. No Particular Unit Value
1 Project cost GBP 49,909
2 Monetary benefit GBP 14,516
3 Debt equity ratio Ratio 2.14
4 Simple payback period year 3.44
5 NPV GBP 28,451
6 IRR %age 27.89
7 ROI %age 13.75
8 DSCR Ratio 1.55
9 Process down time Days 14
Case study : Installation Solar Water Heaterin Solahpur Cluster
S.No Particular Unit Value
1 Project cost GBP 1,117
2 Debit equity ratio Ratio 3:1
3 Monetary benefit GBP 601
4 Simple payback period Years 1.86
5 Net present value GBP 1,104
6 Internal rate of return %age 36.62
7 Return on Investment %age 26.60
8 Average debt service coverage ratio ratio 2.26
9 Procurement and implementation Time
week 10
Estimated Total Saving, Investment & CO2 Reduction of Howrah Cluster
Sl NoEnergy Conservation
Measure (ECM) as per DPR
Total Saving Potential (million
GBP)
Total Investment in
(million GBP)
CO2 reduction Ton/year
1
Air Pre-heater and Drying bed for Galvanizing and Annealing Furnaces 0.189 0.175 1533
2
Air-Pre Heater and Flux Solution Heating for Galvanizing and Annealing Furnaces 0.144 0.048 943
3Air Fuel Ratio Control with Oxygen Sensor 0.171 0.154 1398
4Air Pre Heater for galvanizing and annealing 0.125 0.184 1021
5Biomass Gasifier for Coal Based Furnaces 0.617 0.364 1539
6Biomass Gasifier for FO Based Furnaces 0.023 0.330 1762
Sl NoEnergy Conservation Measure
(ECM) as per DPR
Total Saving Potential
(million GBP)Total Investment in (million GBP)
CO2 reduction Ton/year
7 Energy Efficient Motor 15 kW 0.009 0.014 134
8 Energy Efficient Motor 22 kW 0.007 0.009 105
9 Energy Efficient Motor 45 kW 0.004 0.010 53
10
Air Pre-heater Heat Pipe Heat Exchangers for Galvanizing and Annealing Furnaces 0.027 0.060 198
11 Furnace Insulation Improvement 0.111 0.099 796
12DC motor of 160 kW with AC Motor of 90 kW with VFD 0.035 0.088 359
13DC motor of 260 kW with AC Motor of 180 kW with VFD 0.026 0.065 269
14Temperature Control in Zinc Bath in Galvanizing 0.044 0.076 357
15LPG Gas Fired Radiation Furnace for Annealing 0.096 0.237 1394
TOTAL 1.315 1.912 11863
TECHNOLOGY : ENERGY EFFICIENCY MEASURES
CASE 5 : VAM : AT AN UNIVERSITY CAMPUS (BESU)
• TOTAL ELECTRICAL LOAD : 850 KVA• TOTAL CONNECTED COOLING LOAD : 354 TR• 14 HOSTELS WITH 100 STUDENTS IN EACH : 1400
STUDENTS LIVING IN CAMPUS• PROPSED COGENERATION SYSTEM : TRIGENERATION –
POWER, HEATING AND COOLING• PROBABLE INVESTMENT (GBP): 508,572 • ESTIMATED ANNUAL SAVING (GBP/Yr): 161,568 • SIMPLE PAY BACK (Yr) :3.15 • ROI (%/Yr) : 26.77
SUMMARY : SIMPLE SOLUTIONS
• Energy Modesty• Education & Awareness• Training & Capacity Building• Upcoming Technologies: VAM, Heat
Pump, CHP, Smart Grid, PMM, etc.• International Collaboration• ISO 50001
Awareness, Seminar and TrainingFull time course – two years Master
Degree Energy Management in MPSM Programme under University of Calcutta
Short term course – three months short term course on Energy Management & Audit
Energy Club & AEE – India ChapterEnergy Research & Consultancy
Projects
IISWBM’S ENERGY MANAGEMENT INITIATIVES….SINCE 1993
37
ACKNOWLEDGEMENTS: IISWBM, LOUGHBOROUGH UNIVERSITY,
LCEDN, REFERRED BOOKS, WEBSITES
Questions?Email Please:
[email protected]@gmail.com
THANK YOU
39
ON BEHALF OF
ENERGY MANAGEMENT DEPARTMENT OF
INDIAN INSTITUTE OF SOCIAL WELFARE AND BUSINESS MANAGEMENT
www.iiswbm.eduphone : 2241 3756; fax : 2241 3975
SUSTAINABLE ENERGY AND GHG ACCOUNTING CELL
ASSOCIATION OF ENERGY ENGINEERS - INDIA CHAPTER
www.aeeindia.org
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