Knowledge Exchange Platform Promoting Energy Efficiency through Best Practices in Industries covered under the Perform Achieve & Trade (PAT) Scheme NEWSLETTEr ISSUE-4, SpECIAL EDITION-NECA 2015
INSIDE INSIDE
message from Director General, Bureau of Energy Efficiency
Co-benefits of Driving Industrial Energy Efficiency Best practice Case studies • Bharat Aluminium Company Limited • J.K. White Cement Works, Captive power plant, Gotan • Mahindra Sanyo Special Steel private Limited Small Group Activities for Continuous Quality Improvement Significance of PAT - Perform, Achieve & Trade in Chlor-Alkali Industry Innovative Technology to Promote Energy Efficiency • Jet Towers: Liquid Jet Technology in Cooling Towers • MD Dryers: Energy Efficient Dry Quality Air Systems Knowledge Exchange Platform Initiative - Journey So Far Supported by
The award winning paintings of children who participated in National Level Painting Competition -2015 organised by Bureau of Energy Efficiency, Ministry of Power, Government of India, are presented here. Paintings of Arghadip Paul (Tripura), Adrij Das (West Bengal), Aryan Verma (Himachal Pradesh), Ayush Kr Verma (Bihar), Baraiya Kishan (Gujarat), Binita Biswajeeta (Odisha), Malemnganba Waikhom (Manipur), Monali P. Naik (Goa), Debashree Mahato (West Bengal) appear below in the same order.
Dr. Ajay Mathur Director General, Bureau of Energy Efficiency
Message Warm greetings to all friends and colleagues! At the outset, I would like to extend my heartiest congratulations to the winners of the National Energy Conservation Awards (NECA), 2014-15. This year, the participants to the award program have achieved an annual monetary savings of Rs. 2928 crore with an investment of Rs. 2384 crore, which is highly commendable. The award winners set a powerful example of how individual efforts and commitment to energy conservation and efficiency can contribute to making India energy secure, and inspire other like-minded organisations and industries to focus on strategies and solutions that can enhance their energy productivity. The sheer number of participants and award winners in NECA is a testimony to the large number of successful energy leaders and opinion makers in our industry and the impact they create by sharing their knowledge and learning with other industries. I am happy that through the KEP platform, we are making a concerted effort to harness this vast and increasing knowledge experience and to promote the transfer of best practices on energy efficiency within and across the industry sectors. The industry has also joined hands with KEP in promoting peer to peer learning and exchange of best practices through sector learning groups, sector level workshops and technology exhibitions. So far, we have organised 5 sector level workshops - for the Aluminium, Cement, Pulp & paper, Thermal Power and Textile sectors. Cross sectoral knowledge transfer has also been high on our agenda and we initiated this effort by sharing of best practices in thermal power sector through a workshop and exposure visit for the benefit of other industry sectors having large captive power plants. We are also making efforts at evolving KEP as a forum for sustained interaction between the BEE and Industry that will enable us to have a better pulse of issues and challenges being faced by the industry. In line with this commitment, we have initiated a series of Policy Roundtables. The first one in the series was on the trading aspect of ESCerts (Energy Saving Certificates) followed by one on circular economy, where we had a very strong participation from the Aluminium and Cement industry. We plan the next round table to focus on innovative financing models. I will encourage the industry leaders to provide their inputs and feedback in making these fora more interactive and vibrant. This issue of the newsletter covers case studies from Aluminium, Cement and Iron & Steel sectors, with the aim of illustrating of energy efficiency gains in a range of applications across sectors and their impacts. This newsletter also brings to you, benefits of ‘Small Group Activities’ for Continuous Quality Improvement, as well as an opinion piece from the Alkali Manufacturers’ Association of India. In this issue, we have also provided a technology feature focussing on Liquid Jet Technology in Cooling Towers and MD Dryers - Energy Efficient Dry Quality Air Systems. I look forward to a vibrant partnership in the KEP to promote accelerated energy efficiency enhancement.
Ajay Mathur
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For circulation within the KEP network only
ISSUE-4, SpECIAL EDITION-NECA 2015
Co-benefits of Driving Industrial Energy Efficiency – Ms. Ritu Bharadwaj, Senior Program Manager, Institute for Industrial Productivity, India India is world’s fourth largest energy consumer at 4.3% of global energy consumption, after China (12.4%), US (19.9%) and Japan (4.7%)1. India is also the home to 17% of the world’s population, with a low per capita energy use, which is 33 % of the global average, and which is just 9% of per capita energy consumption in the US2, indicating a significant potential for increase in energy demand in the coming years. As per BP Energy Outlook, India’s energy production is expected to rise by 117% by 2035 while consumption will grow by 128%. This is set to have an impact on our CO2 emissions. At the same time, India is highly vulnerable to climate change due to (i) high levels of poverty, (ii) high population density (iii) high reliance on natural resource based livelihoods, and (iv) an already stressed environment.
faced with the challenge of providing
efficiency through its Perform Achieve
energy access to hundreds of millions
and Trade (PAT) program. While the PAT
having no or little access to electricity.
scheme primarily focuses on reducing
Thus Government’s energy policy cuts
specific energy consumption in highly
across a range of these development
energy intensive industries, but this
priorities. In other words, the focus has
effort is also expected to reap a number
been to implement policies and programs
of environmental, economic, social and
that help in dealing with some of the
health related benefits as outlined in this
pressing problems being faced by the
paper.
country like energy security, livelihoods generation, poverty eradication etc. while avoiding lock in to high carbon growth trajectory. The climate change benefits of these actions are seen as an important cobenefit.
Co-benefits of Energy Efficiency Pathways The role of industry to bring in efficiencies, new technologies and different business models to promote system efficiency is
Led by the Bureau of Energy Efficiency
set to get a major boost under the PAT
(BEE), India has launched a major
program. The investment decisions are,
initiative to promote industrial energy
however, guided by the attractiveness of
India has made a significant announcement of reducing 20 to 25 percent of its carbon intensity by 2020 and 33-35% by 2030 from 2005 levels, and achieve 40% of its cumulative electric power of around 350GW installed capacity from renewable energy sources. This commitment was made with the realization that ‘Energy’ is a key driver for India’s development. Indian industry requires reliable energy supply to fuel economic growth and to create employment opportunities. At the same time, India is also Figure 1: Co-benefits of Energy efficiency-National level 1 2
BP Statistical Review of World Energy 2015 http://data.worldbank.org/indicator
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ISSUE-4, SpECIAL EDITION-NECA 2015
the return on investment and the range of business related benefits and impacts that the company can draw from such investments. While taking an investment decision, it is important to recognize that quite often, energy efficiency projects lead to many multiple benefits beyond just energy savings that can make significant contributions in increasing the plant productivity, profitability and competitiveness. These co-benefits may range from saving of raw material, recycling of waste to improved product quality (and thereby access to better markets) may actually lead to much greater revenue streams than reduced energy bill. Factoring all these co-benefits, therefore, would significantly improve the return on investment, making energy efficiency projects far more attractive. Additionally, there are many social, environmental and health related benefits of implementing
energy saving measures. Although these benefits are not directly linked to profitability, they are equally important in our efforts to drive sustainable and inclusive industry growth. It is also important to note that the choices that companies make in terms of investment in energy efficiency and improvement in their energy infrastructure will also have an impact at a national level. Figure 1 tries to capture the impact of a successful energy conservation drive at the national level. Figure 2 captures the benefit streams of energy efficiency measures at a plant level and the need to consider some of them while making an investment decision. In a growing economy like India, energy efficiency investments sometimes loose out to more competing investment
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options. But in order to make it happen, it is important that we do not remain fixated with just energy efficiency gains, but try and factor all the other co-benefits that come along with energy efficiency investments. This would definitely tilt the scale favourably towards faster implementing of such projects. It is also important to realize the contribution of implementing energy savings measures by way of improving the quality of life of the workers engaged in manufacturing through social, health and environmental benefits. While all these benefits accrue at the plant level, the country also gets benefitted as highlighted in this paper. Through the KEP platform, we would like to urge the industry partners to enrich the co-benefits debate and try and incorporate these impacts in the energy efficiency case studies that are being disseminated through the KEP newsletter.
Figure 2: Co-benefits of Energy efficiency-Enterprise level
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ISSUE-4, SpECIAL EDITION-NECA 2015
Best Practice Case Studies Bharat Aluminium Company Limited – Mr. Ravish Sharma, Bharat Aluminium Company Limited
About the Plant Bharat Aluminium Company Ltd. (BALCO), under the umbrella of Vedanta Resources Plc, has been closely associated with the Indian aluminium industry, playing a pivotal role in making aluminium, which has a myriad uses ranging from household and industrial requirements to aerospace applications. It is well positioned in the key core sector industries, has a strong track record of performance, and is among the fastest growing groups in India. The company started its business in 1965 as a Public Sector Undertaking (PSU). In 2001, the Government of India divested 51% equity and management control in favor of Sterlite Industries Limited. BALCO’s principal strength lies in its dedicated employees across the competencies of mining, manufacture, research, quality, strategy, finance, marketing, environment and people management. The company is enriching the quality of its human resources through selective recruitment, training, motivation, delegation, reward and recognition. BALCO has its own captive power plants
and captive mines at Mainpat and Kawardha. Mining is of the open cast, semi-mechanized type.
Innovative Project: Implementation of Single Beam in Pot line Bharat Aluminium Company Limited (BALCO), Potline 1 consists of 288 GP 320 reduction cells designed for operation at 320 KA. Current is passed through the pots which are connected in series to produce aluminum metal. The major operations carried out in the smelter are metal tapping, anode change and beam raising. The beam raising is carried out using an anode jacking frame (AJF) which rests over the pot and holds 20 anodes at a time (a total of 40 anodes, 20 each on the riser and non-riser sides).The same frame is then lifted and shifted to the other part of the pot to carry out beam raising of the rest of the anodes.
Need for innovation
As per the GAMI design, the beam is of the spilt beam type. There are two separate anode suspension mechanisms which allow normal pot operations, that is, the raising and lowering of anodes Figure 1: Specific Energy Consumption in the clamped on to an aluminium plant (2011-15) busbar/beam. Due to the Specific Energy Consumption (kWh/MT of difference in inertia of the two Aluminium Produced) suspension mechanisms there is always a difference between 14,834 14,900 14,754 14,800 the levels of the two beams and 14,700 14,600 hence that of the anodes, which 14,500 14,358 14,400 results in an overall variation in 14,175 14,300 the hydro magneto dynamics 14,200 14,100 of the pot and leads to voltage 14,000 13,900 fluctuations and increase in 13,800 2011-2012 2012-2013 2013-2014 2014-2015 noise.
Technology adopted BALCO developed technology in-house, with which it was possible to convert the split beams to a single beam using a floating shaft. This technology upgradation was critical to reducing production losses due to voltage fluctuations, and disturbances to the operating pots. The plant has successfully implemented this technology in the pot room and it is now standard procedure for mitigating the risk from the split beam. The impacts are manifested in increased production, energy savings and stability of operating pots.
Methodology adopted Initially, the use of an electro mechanical clutch mechanism on each pot was proposed, keeping the anode jacking frames untouched. This involved developing a mechanism to facilitate engagement of the two suspension assemblies during normal operation and disengagement while raising the bus bar. However, this proposal was rejected because it was technically complicated and expensive. Further discussions drew out the fact that the beam differences could be eliminated by connecting both suspension mechanisms by two floating shafts to overcome the adverse effects of split beams; trials carried out in about ten pots proved to be successful. The one difficulty in using this method was that both the floating shafts had to be removed from the system during beam raising, and then restored. This difficulty was overcome by joining the two anode jacking frames to make one AJF capable of
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Issue-4, Special Edition-NECA 2015
Figure 2: Single Beam Concept
Table 1: 30 Days Trial Phase (21 July 2013 to 20 August 2013) Results Before Modification Cell No
handling 40 anodes together. Now anode raising can be performed in one go thereby eliminating the process of anode raising in parts. An added benefit of this method was that the beam raising time per pot came down from 40-45 minutes to 20-25 minutes. To the best of plant’s knowledge, such a conversion of split beam pots to a single beam has been accomplished done for the first time in the world, in a running smelter.
Implementation strategy adopted A Risk Assessment exercise was carried out before the innovation was implemented with necessary approvals taken and drawings prepared, including drawings for the pot and pot controller system. The modification was implemented in the following steps: Step 1: An arrangement to shift AJFs was required to facilitate beam raising in all sections while the AJFs were refurbished/ modified; to this end a special trailer was prepared, tried and deployed on the field. Step 2: Since the number of AJFs in the potline was going to be reduced, they would need to be more reliable and hence they were taken up for refurbishment. Step 3: Once the refurbished AJFs were made available, two of them were joined together so as to enhance their capability from handling 20 anodes to handling 40 anodes at a time. Floating shafts were installed and changes made to the potcontroller hardware with all necessary interlocks/instruction displays taken up in each pot (room-wise). Modifications were
5
Average Average Voltage (V) Noise (mV)
After Modification
Average bath Covering Collapse (No.)
Average Voltage (V)
Average Noise (mV)
Average bath Covering Collapse (No.)
117
4.258
25
3
4.238
19
1
124
4.271
27
2
4.240
18
0
204
4.248
23
2
4.236
19
0
218
4.252
26
1
4.239
20
0
305
4.249
24
3
4.235
17
1
332
4.243
26
4
4.236
18
1
403
4.240
21
3
4.237
16
0
418
4.242
28
2
4.238
18
0
518
4.239
24
4
4.236
18
1
519
4.244
26
2
4.234
19
0
604
4.241
21
1
4.236
18
0
626
4.239
23
3
4.232
18
0
706
4.251
25
2
4.236
19
0
731
4.234
24
3
4.238
18
1
804
4.249
26
4
4.235
19
0
819
4.242
24
2
4.236
19
0
made in steps to allow pilot runs, during which the performance was assessed, and then later, pots were modified in entire potline. Around ten pots were identified in Section 8 for trial. Floating shafts were installed in these pots and the following changes were made to the pot-controller system: the beam raising operation included A.ABR and all the functions related to B.ABR would be disabled. All 40 anodes were to be unclamped in one go and beam raising would be completed after giving the A.ABR command as done earlier, without needing to give the B.ABR command. Step 4: The first trial was made on Pot No. 806 and pot parameters were assessed for control. The only observation during the first trial was that the crane (PTM) hoist speed was a bit higher than normal and a risk of mishandling the AJF existed. The crane hoist speed was later reduced after getting MOC (Management of Change) approval. Step 5: The same changes implemented in the other room.
were
Trial and Implementation period During the trial phase, about 30 days in 16 pots of the potline, it was found that all pot parameters were improving. These parameters were: • Noise • Average voltage of pot cell • Number of cover collapses in pot • Average voltage fluctuation Upon the trial’s success, an action plan and target dates were prepared for putting the Figure 3: Average Voltage and Noise during Trial Phase
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Issue-4, Special Edition-NECA 2015
Figure 4: Impact of the innovative project on potline noise, voltage swing, average voltage and current efficiency (2013-2014)
Mr. Deepak Prasad Vice President Bharat Aluminium Company Limited
“This is one of the finest energy saving project done in the plant with complete team work. This has set example for others to do improvements in the plant.”
Pictures of before and after implementation
Before: AJF for holding 20 Anodes. Qty for 288 pots-4 Number.
single beam into operation in the potline. All the associated documents, results, action plans, target dates were discussed with the senior management and approval obtained for implementation.
Impacts and Benefits realized • Energy savings: 20 mV voltage reduction in potline and increase in
Team of Innovators
After: AJF for holding 40 Anodes. Qty for 288 pots-2 Number.
current efficiency with reduction in pot parameter fluctuation after anode change. • Financial implications: The total amount of money invested in the project was about Rs. 68.2 Lakhs in FY 2014-15. The monetary benefits achieved were Rs. 13 Crores in FY 2014-15.
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Best Practice Case Studies J.K. White Cement Works, Captive Power Plant, Gotan – Mr. Simrandeep Singh & Mr. Anuj Kumar Tailor, J.K. White Cement Works, Gotan
Introduction Among the most successful strategies industries have at their disposal for controlling electrical energy use and minimizing utility costs is the use of the variable frequency drive (VFD). Incorporating variable frequency drives into applications such as fans, pumps, cooling towers, and crushers, can reduce energy use up to 50 percent at partial loads by matching motor speed to the changing load and system requirements. However, application of VFD as a retrofit option, sometimes poses challenges to engineers. The case study presented here, of a cement plant’s captive power facility provides insights into challenges faced by engineers and ways by which VFD’s can be used to save energy.
Success Story: J.K. White Cement Works, Captive Power Plant, Gotan J.K. White Cement is India’s first white cement facility and uses the dry process technology. The Gotan plant was commissioned in 1984 with an initial production capacity of 50,000 tons. It uses technical expertise from F. L. Smidth & Co. of Denmark and state-of-the-art technology with continuous on-line quality control by microprocessors and X-rays, ensuring the purest white cement. Over the years, continuous process improvements and modifications have increased the plant’s production capacity to 610,000 tons per annum. Owing to its constant R&D efforts and updated technology J.K. Wall Putty, a new, valueadded product was launched in 2002.
Innovative Project: Installation of Variable Frequency Drive (VFD) at Captive Power Plant -Coal Crusher and Primary Air (PA) Fan The Captive Thermal Power Plant (TPP) is situated in the premises of the J.K. White Cement Works, Gotan, and has been running since July 2008. The captive power plant with capacity of 7.5MW uses a coal-fired boiler. The TPP in J.K. White Cement Works has a steam turbine which works on the Rankine cycle principle. Demineralized water (DM) is fed into the boiler by a feed water pump and the coal is fired by high pressure air generated from primary air (PA) fan. Steam generated in the boiler passes to the turbine inlet and then rotates the blade of the turbine at 9000 rpm; the turbine’s rotor is connected to the generator’s rotor via a gearbox. The generator’s rotor rotates at 1500 RPM and has 4 poles which produce 11 KV, stepped down to 6.6 KV and 3.3 KV for the plant’s use. Steam exhaust from the turbine is condensed in an air cooled condenser. The basic functioning is shown in Figure1.
1. Installation of VFD at Captive Power Plant -Coal Crusher Need for innovation In the thermal power plant, the crusher used to crush limestone, coal and lignite has a capacity of 30 TPH. A brief specification of CPP coal crusher is given in Table 1. Table 1: Specification of CPP-Coal Crusher Parameters Crusher Capacity (TPH) Feed Size (mm) Motor(kW) Rated RPM Full Load current (ampere)
Details 30 -150mm to +6 mm 75 1485 132
The plant uses “F” grade quality fuel, with a fines content ofmore than 40%, which can be crushed relatively easily. The crusher motor was directly coupled to the crusher and was running at 1485 RPM even though the crushing required was less; electricity was thus being wasted. Technology adopted The team studying the problem aimed at reducing electricity consumption as well
Figure 1: Physical layout of the four main devices used in the Rankine cycle KEY 1- Low pressure cool liquid 2. High pressure liquid/vapour 3. High Pressure Hot Gas 4. Low pressure Hot Gas
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Issue-4, Special Edition-NECA 2015
Figure 2: Fishbone diagram for identifying the root cause
challenge for the team was to change the VFD application from fan to crusher. Instrumentation experts were engaged, who modified the application. • Welding work during cable mounting at the crusher set some coal particles on fire which burnt the cable. A water line was arranged to continuously spray water on the floor.
as the fines generated in the fuel. To this end, the team decided to install a variable frequency drive (VFD) which would allow control of the crusher motor’s speed, reducing electricity consumption, and would also cut down the fines generated.
prepared to understand the root cause of problem.
Methodology adopted
Problems faced during implementation and their solutions
The team used brainstorming sessions, departmental meetings and a root cause analysis tool to analyze the problem. A fishbone diagram (Figure 2) was
The process was carried out stepwise through an implementation plan structured by the team and shown in Table 2.
• The engineering team decided to use a spare VFD which had been set earlier for an ACC fan application. The
Table 2: Implementation plan to reduce the power consumption of crusher drive Action 1
Jul-14
Identification of significant drive
Aug-14
Nov-14
Dec-14
2
Feasibility study at site
3
Indenting variable frequency drive
4
Installation of VFD with modification of logic in PLC system for variation in RPM of crusher drive
5
Observation of the drive and monitoring of the system
CRUSHER Motor - kW
Power Consumption by Crusher Motor, before VFD installation–kW
Crusher Motor runninghrs/ day (average)- at Full Load (h/day)
Average Power Consumption per day - before VFD installation - kWh
Power Consumption by Crusher Motor, after VFD installation kW
Average Power Consumption per day - after VFD installation - kWh
Power Saved – kWh /day
37.97
13.00
493.64
19.64
255.33
238.31
75.00
14 Dec - 14
Powersaved – kWh perday: 240kWhover a 13 hrs running period.
Table 4: Impact on Crusher motor current drawn and fines generated before and after VFD installation Current drawn on feeding (in amp) Before VFD Installation-Full RPM 58.00
After VFD Installation-at 1250 RPM 28
Fines < 1mm Before VFD Installation-Full RPM 50%
After VFD Installation - at 1250 RPM 44%
Savings in current drawn (amp) 30.00
• The next challenge was to reset the VFD application from fan speed control to crusher speed control; until then, the fan motor’s speed could be controlled only from the VFD panel. In the crusher motor speed application, the frequency/ speed had to be controlled through the SCADA system (supervisory control and data acquisition, a computer system for gathering and analyzing real time data). New logic was defined in the PLC to allow control by the SCADA system. Trial and Implementation period
Table 3: Power consumption by crusher motor before and after VFD installation Date
• A problem anticipated by the team was with an old, small terminal box in which the windings were very close. It was apprehended that any coal dust settling on the coils could cause flashing and hence short circuit the terminals. The team decided to replace the old terminal box with a new, larger one, to circumvent the problem.
As per plan the trial was conducted in December,2014 after the VFD was installed; observations and the outcome of the trial are shown in Tables 3 and 4. Impacts and benefits • Energy savings: On an average, the total energy savings achieved per day was about 231.77 kWh (considering 12.84 hours running per day) • Financial implications: The total amount of money invested in implementing the project was about Rs. 4.50 lakhs. The monetary benefits achieved were Rs. 5 lakhs per annum. • Payback: The payback period is short, at 10.8 months, which makes the project attractive for replication.
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Figure 3: Fishbone diagram for identifying the root cause
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decided to install a variable frequency drive (VFD) in the PA fan (drive) so that fan speed could be adjusted to the primary air flow and discharge pressure. The damper on the discharge side was kept fully open because air flow and discharge pressure were controlled by fan speed only. The process was carried out stepwise using an implementation plan structured by the team as shown in Table 5. Problems during implementation
Table 5: Implementation plan to reduce the power consumption of PA fan drive Action 1
April-15
Identification of drive
May-15
July-15
August-15
2
Feasibility study at site for the modification
3
Indenting variable frequency drive
4
Installation and commissioning of VFD
5
Observation of the drive and monitoring of the system
2. Installation of VFD at Captive Power Plant- Primary Air (PA) Fan Need for innovation In a thermal power plant, a primary air (PA) fan supplies high volumes of preheated, primary combustion air to move pulverized coal into the boiler and drive off excess moisture. In this plant, the PA fan’s shaft is directly coupled to the motor (rating of 55 kW, 2960 RPM). A damper, placed at the discharge end of the PA fan was being operated manually and hence, was not synchronized with the boiler’s fluctuating load, resulting in power wastage and inefficient boiler operation.
Methodology adopted The team used brainstorming sessions, departmental meetings and a root cause analysis tool to analyze the problem. A fishbone diagram (Figure 3) was prepared to understand the root cause of problem. Technology adopted Fan discharge air pressure and flow requirement were both controlled manually, so the aim of the intervention was to optimize the process by reducing electricity consumption and also removing manual control. The team thoroughly investigated the situation and
• The VFD installed for the PA fan did not respond to the start command. This could have been because of problems in feeding parameters in to the VFD system in the initial stages. This issue was resolved by restoring factory settings and feeding in the parameters again. • The VFD’s speed was not visible on the PLC (Programmable Logic Control) screen. (The PLC is a purpose-built machine control computer designed to read digital and analog inputs from various sensors, execute a user defined logic program, and write the resulting digital and analog output values to various output elements). Checks on the panel revealed problems with the wiring which rectified the problem. • The coal feeders did not start when PA fan was in operation, which infact should start as there was a feedback interlocking with PA fan. Checks on the panel revealed problems with the start operation feedback for coal feeders,
Table 6: Power consumption by PA fan before and after installation of VFD Before VFD Installation Date
After VFD Installation
Power generated in TPP(MW)
Power consumed by PA fan (without VFD) in MW
2-Jun-15
179.00
0.953
3-Jun-15
179.00
4-Jun-15
179.00
5-Jun-15
180.00
Date
Power generated (MW)
Power consumed by PA fan (with VFD) in MW
Power Saving per day in MW
2-Aug-15
180.00
0.689
0.264
0.953
3-Aug-15
179.00
0.689
0.264
0.953
4-Aug-15
179.00
0.689
0.264
0.953
5-Aug-15
179.00
0.689
0.264
Total power saving per day 264 kWh considering full load
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which rectified the problem. • During creation of face plate for PA fan VFD drive on SCADA, the team was not able to access process value and set point as PLC addressing and SCADA addressing was not mapped properly. The mapped value of PLC and SCADA were checked properly and changes were incorporated, which enabled the plant to access process value and set point. Trial and Implementation period As planned, a trial was conducted in August, 2015 after installing the VFD and
Issue-4, Special Edition-NECA 2015 observations and outcomes of the trial are shown in Table 6. Impacts and Benefits • Energy savings: The total amount of energy saved per day was 264 kWh. • Financial implications: The total amount of money invested in the project was about Rs. 4.5 lakhs. The monetary benefits achieved were Rs. 5.7 lakhs per annum. • Payback: The payback period is short, at 9.5 months, which makes the project attractive for replication.
Team of Innovators The team behind the successful implementation of the project were (Left to right) - Mr. Vikram Rajpurohit (Dy. Station Manager-Thermax), Mr. Rahul Dwivedi (Dy. ManagerInstrumentation, JK White), Mr. Kamal Goyal (Station Manager-Thermax), Mr. Sanka Chaudhary (Senior Engineer- Electrical, Thermax) and Mr. Anuj Tailor (Asst. Engineer-CPP, JK White).
Mr. B K Arora President (Works), J.K. White Cement Works, Gotan (Rajasthan)
“Installation of Variable Frequency Drive (VFD) at CPP Coal Crusher and Primary air (PA) fan is an excellent example of committed team efforts and total employee involvement for reduction in auxiliary power consumption at CPP. Adoption of structured approach along with use of proper root cause analysis tool, successfully implemented the project in a short time which gives saving of 500kWh/ day and makes the project more attractive with a payback period of less than 1 year.”
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Best Practice Case Studies Mahindra Sanyo Special Steel Private Limited – Mr. Utsav Tayade, Mahindra Sanyo Special Steel Private Limited
About the Plant Mahindra Sanyo Special Steel Pvt. Limited (MSSSPL) was established in 1962 (erstwhile MUSCO) and is located in Khopoli, District Raigad, Maharashtra. It is in the business of manufacturing special steel products for various industrial segments – automotive, bearings, capital goods, tool and dies, oil, gas and mining etc. It produces steel through the electric arc furnace route with various downstream shapes and conditions i.e. as cast, rolled, forged, heat treated, rings and gear blanks. Some of its major customers are Maruti Suzuki, Mahindra & Mahindra, Ford, John Deere, Timken, SKF, FAG, Nachi, NSK, Schlumberger, Halliburton, Sandvik, Cummins, Toshiba and Cummins India. Saving energy ranks as one of the high priority initiatives of the company’s business strategy for two reasons: firstly, steel manufacturing through electric arc furnace route is highly energy intensive and secondly, power tariff is continuously increasing thereby posing a competitive strain on the Company.
MSSSPL’s Sustainability Journey The vision statement of MSSSPL is to become the most admired, successful and socially responsible special steel manufacturer in India by 2019. It has chosen the path of sustainability to achieve this goal and is working on issues such as power and oil saving, installation of renewable energy, water conservation, waste-to-wealth conversion through circularity, reducing resource intensity for minimizing extraction by way of recycled inputs and yield improvement, stakeholder engagement and Life Cycle
Analysis. Targets have been set for each of these material aspects which are reviewed regularly by the top management.
Journey towards energy efficiency improvement Energy Management is a part of the plant’s five year roadmap in order to achieve the set goals. The following steps were taken to set up the energy management system: • Implementation of Plan-Do-Check-Act (PDCA) for reducing energy intensity under EnMS ISO 50001. • Regular internal and external energy audits for identification of key improvement areas and verification audits after implementation of the same.
management, workmen and contractual labour and then implementing the suggestions on priority basis and sanction of budgets based on cost – benefit aspects. • Larger projects are identified in advance for capital budget sanctions.
Roadmap for to achieving energy efficiency Short-term • State-of-the-art electrode regulation system was installed in the Electric Arc Furnace to ensure greater precision, automation and also uniform heating of the ladle to reduce hot spots. • Revamping of furnaces for greater efficiency.
• Creating awareness through technical trainings.
• Replacing old pumps with energy efficient pumps.
• Installation of centralized energy monitoring system for real time monitoring.
• Oxy-fuel up gradation for remaining chamber furnaces.
• Regular monitoring and measurement and energy reviews through daily, weekly and monthly meetings. • Gap analysis carried out to compare target v/s actual for process and equipment. This is done through weekly meetings and corrective actions are taken to bridge the gap. • Implementing improvement projects through kaizens and QC story approach. • Equipment delay management through preventive maintenance.
• Installation of transparent roof tops and use of LED Lights to reduce lighting load. Long-term In the last four years, the plant has reduced specific energy consumption in Electric Arc Furnace by 17% by implementing several innovative projects. In the next 3 years, the plant plans to achieve energy efficiency through the following major projects: Projects in Steel Melting Shop:
• Benchmarking against best available technologies in steel industry.
• Waste heat recovery from Electric Arc Furnace.
• Conducting theme based suggestion meetings involving all employees,
• Installation of Virtual Lance Burners in Electric Arc Furnace.
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Figure 1: Results of the initiatives implemented to reduce energy consumption and roadmap
Projects in Renewable Energy: • Installation of 2 MW Solar power • Hydro Power Procurement of 3 MW The vision is to achieve 20 % of power generation through the above identified renewable projects.
Innovative Project: Oxy-Fuel Technology for Reheating Furnace
Figure 2: Reduction in energy consumption in Electric Arc Furnace
KWH/MT
EAF Power KWH/MT 600 580 560 540 520 500 480 460 440 420 400
586
525 498
F 12
F 13
F 14
501 482
F 15
Year Figure 3: Overall reduction in energy consumption (2013-2015)
F 16 H1
Combustion in the furnace involves fuel, oxygen and ignition. Oxygen comes from ambient air which has 78% nitrogen and 1% argon by volume. However, nitrogen does not take part in combustion process but absorbs the heat and cools down the furnace, which means that more fuel is needed to maintain furnace temperature. Therefore, when oil is burnt in ambient air, large amounts of flue gas are generated, with nitrogen as the major constituent. This volume of flue gas released can be reduced and combustion efficiency improved by removing nitrogen from air, leaving only oxygen for combustion. This is the principle of Oxy-Fuel Technology. Oxy-Fuel combustion improves heat transfer as the products of combustion, CO2 and H2O, have higher partial pressures compared to products when air is used as fuel. When Oxy-Fuel Technology is used, exhaust gases are not diluted with nitrogen and the gas phase of combustion process will play a more active part in heat transfer in the furnace, not only because of the heat Figure 4: How Oxy-Fuel Technology works
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Figure 5: Reduction in fuel consumption after implementation of Oxy-Fuel Technology
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Figure 6: Emission reductions achieved after implementation of Oxy-Fuel Technology
Emission Reduction
80 70 60 50
Before Oxy-Fuel
40
After Oxy-Fuel
30 20 10 0 SPM (mg/Nm3)
capacity of CO2 and H2O and higher heat transfer conductivity but also because they are both highly heat-radiating gases as well.
Need for Oxy-Fuel Technology The price of oil was quite high and the oil consumption of current furnaces in the plant was much higher than the set benchmark because of two reasons viz., the existing furnace was 33 years old and the air/oil flow ratio was manually controlled. This project was an outcome of Life Cycle Analysis which suggested that the specific oil consumption could be decreased by 50-55 % and that auxiliary power consumption of the furnace could be reduced with reduction in environmental impacts. Finally an auto air/flow system using a programmable Logic Controller (pLC), and a new high pressure burner system was set up, in addition to using OxyFuel Technology.
Team of Innovators
Impacts and Benefits of Oxy-Fuel Technology • Removal of nitrogen ballast from the combustion and heat transfer process, as combustion air is replaced with industrial grade oxygen. • Reduction in emissions of sulphur and nitrogen oxides and SPM leading to 80% reduction in volume of flue gases. • Burner maintenance became easier and a uniform flame was achieved which helped uniform heat distribution. • Reduction in time taken for material to reach a set point temperature in comparison to an air fuel fired furnace. • Boosting of furnace throughput by up to 50%. • Smaller and user-friendly flue gas handling system. • Reduction in fuel consumption by 5055%. • Decrease in power consumption by 50%.
SOx (kg/h)
NOx (mg/Nm3)
Mr. Uday Gupta Managing Director, Mahindra Sanyo Special Steel Pvt. Limited
“We are committed to optimize our energy use in our entire operation. We will continually improve the energy performance of all equipment and processes in alignment with our business strategy and also with National Mission and guidelines that reflect our care for the planet and society.”
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Small Group Activities for Continuous Quality Improvement Experiences of Vedanta Limited (Aluminium plant), Jharsuguda – Mr. Bijneswar Mohanty, Vedanta Limited (Aluminium plant), Jharsuguda
Small Group Activities- Concept Small group activities are activities carried out voluntarily and continuously by all members of small groups within the same work place aimed at improving the operation of the work place in line with company policy. In other words, companies are a gathering of people, and individual people come together and form a place of work. If every worker is well trained and able to display his or her full potential doing work that is satisfying and fulfilling, the work place will be lively and bright and the company will continue to grow and prosper. One of the ways of achieving this is through small group activities.
Small Group Activities at Vedanta Limited (Aluminium plant), Jharsuguda
All these activities were given a boost by regular in-house competitions and have won the plant the coveted Par Excellence awards at the state, national and international forums of the Quality Circle Events. Using the DMAIC strategy, part of the Six Sigma, initiative, another vital Small Group Activity has been in practice at the plant since October 2012 and has steadily built up a defect-reducing mechanism through a project-based-improvement culture. Similar activities were carried out for energy saving initiatives engaging over 150 employees; over 100 projects were completed leading to energy savings of 1200 kWh/MT over five years. The plant encourages their contract partners to participate in energy activities such as energy saving suggestion schemes, brain-storming sessions, energy audits, quality circles and kaizen-based
Box 1: Why small group activities?
• To develop work that is satisfying and fulfilling by raising workers’ capabilities and making effective use of their ingenuity. • To create a lively and bright workplace by respecting the human qualities of the workers. • To contribute to the improvement and development of the company. projects. The best energy saving projects are awarded as part of the Monthly Best Performer Award scheme by the senior management to motivate and encourage participation in energy conservation initiatives. The SGAs at Vedanta Limited strive for promotion of the team work mechanism to address priority business projects.
There has been a steadily growing diffusion of Business Excellence Initiatives into the way employees work across the entire Jharsuguda location since 2012-13. The journey began by focusing on enhancing attitudes and building continuous-improvement-mind-sets. A continuing Quality Circles (QCs) campaign was launched in which all frontline employees, in the presence of their managers, were apprised of Small Group Activities and their ability to enrich the quality of their work-life and productivity. The QCs were formed voluntarily, promoting creativity and innovation across the location. This initiative has blended smoothly with others such as energy management, 5S, the Asset Optimization (AO) framework, etc. and promoting greater teamwork.
Team of Innovators
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Glimpses of a few Small Group Activities and implemented projects (2014-15) Project 1: Load optimization on the centrifugal fan to reduce the back pressure as also energy consumption. Description of the energy conservation measure: The suction line of centrifugal fans in the Fume Treatment Plant (FTP) area were modified by reducing the suction opening, which helped to reduce current from 5.4 A to 4.4 A without affecting the process requirement of flow and pressure (0.39kpa). An additional benefit was reduction in back pressure over the fan by reducing the vibration of the impeller. Picture before modification
Picture before modification
Fan with modified suction line First year energy saving of 3745kWh with nil investment
Project 2: Re-melting and spillage reduction of cast iron metal in rodding shop. Description of the energy conservation measure: Reduction in spillage of molten cast iron metal, used for fixing of rod into anode, was achieved by the following: 1. Modifying spout length (as shown in photo below). 2. Improving casting cabin visibility with necessary modifications in the operator location. 3. Engaging a person to remove sticky bath from stems at rod inspection station temporarily. Picture before modification
Picture before modification
Change in dimension of spout
Metal spillage
Team responsible for modification
Energy savings of 740,950kWh in the first year with nil investment
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Significance of PAT - Perform, Achieve & Trade in Chlor-Alkali Industry – Ms. Harjeet Kaur Anand, Joint Director (Tech.), Alkali Manufacturers’ Association of India (AMAI) The chlor-alkali sector is one of the eight energy intensive sectors notified under the PAT Scheme with specific energy saving targets. In the chlor-alkali sector the identified threshold limit for becoming a designated consumer was 12000 metric tonne of oil equivalent and in the first PAT cycle 22 designated consumers from various states were notified. The chlor-alkali industry considered the PAT scheme as an opportunity to install mechanisms for successful performance and to improve profitability through incentives for cleaner and energy efficient measures. Associated with market mechanism, PAT brings revenue opportunity and brings in competitive spirit.
Box 1: Elements of First PAT Cycle (2012-15) 1. Target Setting: It is based on gate-to-gate specific energy consumption (GtG SEC). Each designated consumer has to reduce its SEC in target year April 2014- March 2015 as compared to the baseline year April 2009 - March 2010. The targeted reduction is based on efficiency in the baseline year; more efficient units have lower targets than less efficient ones. 2. Monitoring and Verification: Designated consumers monitor and record their energy purchases and product sales. Data is provided to SDAs and the BEE. Data will be verified by an accredited energy auditor for verification and check verification. 3. Incentivization and Trading of Excess Savings: Energy Saving Certificates are issued for savings in excess of target. Certificates can be traded with designated consumers in other sectors also who can utilize them to show compliance. Certificates can be banked for one more Cycle. Trading will be done on the two power exchanges - IEX and PXIL. 4. Penalty for Non-Compliance: The quantum of non-compliance is the deficiency in meeting the target at the end of the Cycle. Penalty is the energy cost of the quantum of non-compliance. The quantum of non-compliance is provided in the verification report and the penalty adjudicated by the SERC.
The chloralkali sector in PAT CycleI (2012-15)
over the past few years as described in
1. 22 Designated Consumers (DCs) notified in the chlor-alkali sector for the first PAT cycle.
PAT will enhance the cost effectiveness
2. National Energy Savings Target: 6.6 million MTOE (metric tonne of oil equivalent) 3. Energy savings target for chlor-alkali sector: 0.054 million MTOE (0.81% of total energy saving target) 4. Benefit of compliance: One tradable ESCert (energy saving certificate) issued/MTOE energy saving achieved to the industry if the savings are more than the target set for the plant.
For Chlor-Alkali Industry Specific Energy Conservation is essential for a unit to survive. It has become possible with technology upgradation
Table 1.
of
energy
efficiency
improvement
schemes and will accelerate the shift to
Japan. It is relevant to mention here that all the technology suppliers have standardized the Electrolyzer Design for 6 kA/m2 operations at 32% caustic concentration and a caustic temperature of 90 °C.
technologies offered by the major suppliers
Energy efficiency improvement in the chlor-alkali Industry
are ThyssenKrupp Industrial Solutions,
• The industry already operates at a very
Germany; IneosChlor, UK; and Asahi Kasei,
high level of energy efficiency; almost
the newer technology. Currently, in India,
Table 1: Technology upgradations and energy parameters S. No.
Technology
Energy Parameters
1.
Mercury Cell
2900 kWH ± 10 kWH per MT 4.20 Volts ± 0.01 Volts
2.
Membrane Cell
2320 kWH ± 10 kWH per MT 3.3 Volts ± 0.01 Volts
3.
Finite Gap
2210 kWH ± 10kWH per MT 3.15 Volts ± 0.01 Volts
4.
Zero Gap
2050 kWH ± 10 kWHper MT 2.95 Volts ± 0.01 Volts
5.
Oxygen Depolarized Cathode
1600 kWH ± 10 kWHper MT 2.35 Volts ± 0.01 Volts
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Box 2: Developments in Chlor-Alkali Manufacturing Technology Developments in Membrane Cell Technology have reached a dead-end. Further reduction in specific energy consumption, either for electrolysis and/or for auxiliary/utilities does not seem to be feasible as of now. The industry’s savior, in terms of long term sustenance could Oxygen Depolarized Cathode Technology for chlor-alkali production. However, this new technology is associated with two limitations, one, that hydrogen is not produced,
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• Involvement and commitment of top management essential to plan capital outlay for energy saving measures, adequate training. The staff and the operating personnel should be properly trained and exposed to the dynamics of PAT schemes.
and, two, that oxygen is needed in the electrolyzer. A unit could have production facilities using both, Oxygen Depolarized Cathode Technology and Membrane Cell technology so that some hydrogen (from the Membrane Cell Plant) is available to make hydrochloric acid, at least for in-house consumption, and where sale of hydrogen offers value addition. The industry may also plan to import hydrochloric acid for other consuming industries, should Oxygen Depolarized Cathode Technology become dominant for chlor-alkali production in the country. This could be possible for new production facilities which could be constructed using this hybrid configuration. ThyssenKrupp and Covestro are also working on the feasibility of retrofitting existing membrane cell plants to switch over to ODC technology, on a case-to-case basis.
all member units are using energy
Ways to proceed further
efficient Membrane Technology.
• Focus on conventional projects.
• Conventional
projects
on
energy
saving should have already been completed. • Further
improvement
adopt energy saving measures based on cost benefit analysis.
is
possible
through technology upgradation to the Oxygen Depolarized Cathode (ODC) technology. This technology is now proven but is capital-intensive and associated with a high payback period. No hydrogen is produced during this process.
• Review technological changes and
Industry thus would also
have to work out Cost Benefit Analysis depending upon the conditions and parameters like Oxygen availability and its Cost and Hydrogen utilisation and its market value besides the cost of power. Therefore, it will be on case to case basis. • Potential for energy saving in chloralkali sector is extremely limited for future PAT Cycles. Industry seeks financial support from Government to
• Utilise PAT and improve the cost economics. • Seek incentives from Government to implement capital intensive energy saving projects. PAT challenges for industry • Industry has to move towards clean and advanced energy efficient technologies, conserving energy and also improving profitability. • Payback schemes should be properly structured within the industry so that investment in new energy efficient technology can be justified. • Revenue loss as heavy penalties are imposed in case of non-compliance in achieving PAT targets.
undertake Capital Intensive Projects
• Very important to understand the
of energy saving, particularly for ODC
scheme and normalization concept
Technology.
fully.
In PAT Cycle I, the target set by BEE was exceeded by most DCs in the chloralkali sector, testimony to the proactive measures taken and best practices adopted by the industry. Initiatives taken by the chlor-alkali industry to conserve energy • The chlor-alkali industry saved over 50,000 MTOE in last 3 years, under the PAT Scheme. • Massive monitoring programmes undertaken to save electricity distribution losses, promoting use of LED bulbs, use of Star Rated equipment, avoiding wastage of energy for better energy performance. • 82% of the industry has installed captive cogeneration power plants to use both heat andpower in the process. • To use hydrogen gas as a fuel for flakes production, steam generation, etc. • Continuous adoption and amalgamation of new advancements in process operations. • Implementation of ISO 50001 Energy Management System (EnMS) as an energy conservation initiative and also as a tool for achieving the PAT targets.
Energy Efficiency Measures Adopted by the Industry 1. Replacing Steam Ejector with WaterRing Vacuum Pump for Brine Dechlorination The de-chlorination process requires a vacuum of the order of 400-450 mm Hg for sucking the excess free chlorine from the
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anolyte which is at a temperature of 85 °C ± 2 °C, at the outlet of the electrolyzer. Generally, steam ejectors are used to generate the required vacuum for de-chlorination. A water-ring vacuum pump is claimed to be more effective than a steam ejector in the following ways: a. Lower operating cost
b. Possibility for augmenting capacity up to 650.0 mm Hg
Benefits are much higher if the ejector steam requirement is met through the pressure reducing and de-superheating station. Figure 1: Steam Jet Ejector v/s Vacuum Pump
Cost-benefit analysis Reference plant: 250 TPD Annual savings: Rs. 4 lakhs MTOE savings: 25 Investment: Rs. 3.5 lakhs Payback period: 11 months (without PAT) and 6 months (with PAT benefits)
2. Installing Thermo Compressor and Utilizing Flash Steam in the First Effect Heat Exchanger 1. To maintain the temperature of caustic around 130 °C, steam is consumed at 8 kg/cm2 (ksc). 2. The caustic concentration increases by flashing. In the process, flash steam at a low pressure of 0.1 ksc is generated 3. Technology: a. The flash steam generated at 0.1 ksc can be compressed to 3 ksc using a steam thermo compressor and reuse the same in the plant. b. Excellent potential to convert low pressure to high pressure steam by installing a thermo compressor c. Live steam at 10kg/cm2 (ksc) as a motive steam in the thermo compressor is used to compress flash steam. Figure 2: Thermo Compressor for Flash Steam Recovery
Cost-benefit analysis Reference Plant: 250 TPD Annual savings: Rs. 35 lakhs MTOE savings: 230 Investment: Rs. 47.5 lakhs Payback period: 16 months (without PAT) and 10 months (with PAT benefits)
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Innovative technology to promote Energy Efficiency Jet Towers: Liquid Jet Technology in Cooling Towers – Mr. Shailesh Harani, Managing Director, AMREC Group Jet-type fanless cooling towers work on water/liquid jet principle. The water to be cooled is circulated through specially designed nozzles, which are located at the top of the jet tower. These nozzles are arranged in such a way that the water flowing out of the nozzles covers the entire top cross sectional area of the jet tower. The water flowing out of the nozzles is in the form of small droplets (with high momentum) falling in an umbrella-like pattern. Spraying in this manner creates a low pressure zone below the nozzles. The spray provides a large contact area as well as contact time between air and water. Fresh air from outside is drawn in because
of the pressure difference, giving rise to a continuous “induced draught”. Excellent cooling is achieved because water and air are in direct contact with each other without any obstacle in between.
Features of Jet-type fanless cooling towers • Maintenance free: Since there are no fans, fills or gear boxes, there is no related maintenance. • Energy efficient: In cooling towers of this kind, there are no electricityconsuming motors; they can be designed using the unique ‘no driftlosses’ design, saving water.
Figure 1: Jet-type fanless cooling towers
• Expansion of presently running cooling towers is possible • Capacity available: 5 m3/hr to 2000 m3/hr single cell; higher capacity possible in multicell configuration. Jet cooling towers can be used for a wide range of applications, right from Air Conditioning to effluent cooling, that is, low delta T to high delta T, total range is covered. • Jet towers can be installed in all kinds of environments including those with high wet bulb temperatures, high ambient temperatures, dry and hot areas, areas with high humidity and so on.
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Figure 2: Installation of Jet Cooling Towers at GT2 Power Plant, BPCL site.
• This technology is being used in different industries, viz. sugar, pulp and paper, aluminium, cement, fertilizers, iron and steel, chemicals, pharmaceuticals, forging, glass, thermal power plants, hotels, hospitals, rubber, agro based plants, commercial buildings, plastic, textile, petroleum and automobiles.
Case Study: Installation at Bharat Petroleum Corporation Limited Bharat Petroleum Corporation Limited (BPCL) is an Indian state-controlled oil and gas company with its headquarters in Mumbai, Maharashtra. The Corporation operates two large refineries located in Mumbai and Kochi.
The Jet cooling tower of 550 m3/hr capacity was installed at the Gas Turbine 2 power plant in 2014 in Kochi refinery, with the following key features: • The fanless cooling tower has no fills or rotating parts and is virtually maintenance-free. • Reliability issues due to fan failure, dislocation of distribution header branch pipes, disintegration of fills and its carry over have been eliminated. • Drift losses are reduced due to extended sump • Fast installation.
were saved upon removal of the two induced draft fans in the old cooling tower. • Financial implications: The total amount of money invested in implementing the project was Rs. 55 lakhs and Rs. 25 lakhs have been saved per annum.
About the technology supplier ARMEC Group is based in Mumbai and manufactures user friendly Induced Draught Fan less Jet Type FRP Cooling Towers without fans and fills.
Impacts and Benefits • Energy savings: The absence of fans in this type of cooling results in savings of electrical energy about 30kW of power
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Innovative technology to promote Energy Efficiency MD Dryers- Energy Efficient Dry Quality Air Systems – Mr. Arnab Maitra, Key Account Manager, Atlas Copco, India Compressed air is used for process requirements, to operate pneumatic tools and equipment, and to meet instrumentation needs. As compressed air leaves the compressor and cools during transport, the water vapour which accompanies it condenses. This water must be removed from the compressed air system to avoid damage to components and products. About 65% of moisture in compressed air is removed at the aftercooler. This is sufficient for many plant air applications such as cleaning, atomization, etc. However, for applications such as instrumentation and pneumatics, air must be dried further.
Energy Efficient Dry Quality Air System Need for compressed air: When air is compressed, the concentration of water vapour and particles in it increases dramatically. The compression process causes the water vapour to condense into droplets, and when this mixes with the high concentration of particles, an abrasive mixture is formed that, in many cases, is also acidic. Without quality air equipment, much of this corrosive mixture will enter the air network. Effective air treatment equipment is an investment with a solid return: it efficiently reduces the contamination in the air that would corrode the pipework, lead to premature pneumatic equipment failure and cause product spoilage. The high cost of low quality air: When it comes to tools, machines and instruments, poor air quality will cause more breakdowns, repairs and replacements. In addition to expense, the resulting
downtime and production delays will be more damaging than any repair. The threat to reputation: When compressed air comes in contact with the product, its stability, scrap rate and final quality can be significantly affected by contamination. Aside from the cost associated with correcting is the irreparable damage to the product and company’s reputation. Moisture, an avoidable threat: Compressed air entering the air network is always saturated with water vapour which, upon cooling, will condense and damage any air system. The amount of condensed water is directly proportional to the air flow and although an aftercooler will eliminate about 65% of the moisture, what remains can still be very destructive.
example, a dew point of 3 ºC at 7 bar (g) means that no water will condense from the air until it goes below a temperature of 3 ºC. The most commonly used dryers in the industry are: 1. Refrigerant type, and, 2. Adsorption type, which in turn, can be of the following three types: a) Blower reactivated type b) Heatless purge type c) Heat of compression (HOC) type
MD Heat-of-Compression Dryer
The Heat-of-Compression Dryer is based upon a breakthrough in drying technology where the operating cost is zero or very small. Compressed air, directly from compressor discharge (before the aftercooler), which is at a higher temperature, is used to regenerate the dessicant.
The performance of a dryer is quoted in terms of ‘pressure dew point’, which is the temperature at which water vapour will start to condense out of the air. For
This device (MD Dryers) eliminates moisture without capacity loss or damage to the system. It ensures a reliable process and good quality end-products by
Working Principle of MD Dryers
MD Dryers
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Issue-4, Special Edition-NECA 2015 Environment friendly • Small amount of desiccantneeded. • 100% oil-free condensate; no further treatment required. • Silent operation. • Total absence of CFCs. • Small carbon footprint. The MD series is specially designed for use with the industry standard Z series of oil-free screw compressors. Together, they form the optimal combination for top quality dry air at a low running cost. The flange-to-flange hook-up design greatly facilitates installation, and all connection parts and bypass components are included in the package.
All-in-one full feature design ZR Compressor with MD Dryer Installation. supplying dry air to a compressed air system, with a pressure dewpoint of -20 °C to -40 °C (under reference conditions). Whereas other desiccant dryer types can consume up to 20% of the compressed air, the MD dryer guarantees 100% flow capacity at the output. Energy efficient, environment friendly Because of the MD dryer’s unique design only a small amount of desiccant is required,typically 5% of that needed by conventional two-tower dryers of the HOC type. Since compression heat is used for regenerating the dryer rotor, the only energy needed is the power to rotate the drum, just 0.12 kW.
• Designed for use with oil-free Z-screw compressors. Fully automatic operation
By integrating the MD dryer and the variable speed drive into one compressor package, the full feature Z series oilfree screw compressor offers the most compact dryer/compressor combination in the industry.
• Simple but efficient control system with dewpoint indicator.
The integration has many advantages:
• Intelligent electronic water drains with alarm function.
• Common monitoring display.
• On VSD models, motor controlled by compressor regulator. Minimal downtime
• One overall operation control system. • Reduced pressure drop. • VSD drive on both compressor and dryer motor. • Occupies little space.
• Long service intervals. no
The full feature units are available as air and water cooled models.
• Heavy-duty internal protective coatings.
• Direct flange-to-flange mounting.
ND dryers: For stable pressure dew point requirements of below -40 °C, the supplier supplies efficient ND dryers, which also work on the MD Rotary Drum-type Heatof-Compression technology.
Performance and air quality
• All piping and connections included as standard.
About the technology supplier
• Low pressure dewpoint of -20 °C to -40 °C (under reference conditions).
• No pre-filter required because of builtin separator.
• 100% oil-free process.
• No dust generated, hence no need for after-filter.
MD VSD dryers are fitted with variable speed drives, reducing the power required still further.
• Continuous operation, no switching or cycling. • No pressure or temperature peaks.
• No depletion consumables.
of
materials,
• Easy-to-service, compact vessel. Easy installation
• Integrated design, occupies minimal space in the facility.
MD dryers are marketed in India by Atlas Copco and for further details on the product, suitability, cost economics, etc., can be obtained directly from the company.
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Knowledge Exchange Platform Initiative The Knowledge Exchange Platform (KEP) was launched on 26th February, 2015 by the Bureau of Energy Efficiency (BEE) in partnership with Institute for Industrial Productivity (IIP) for transfer of best practices in industries covered under the Perform Achieve and Trade (PAT) scheme. The British High Commission, India, is also supporting IIP in this initiative. PAT is a flagship initiative of BEE, which is a mechanism for promoting energy efficiency in large industries. The Knowledge Exchange Platform (KEP) aims to promote energy Release of Action Plan and Newsletter efficiency and Energy Management System (EnMS) as a means of achieving continuous improvement in energy efficiency in the industry sector. KEP will capitalize on these opportunities through following: • Facilitate exchange of knowledge and information within a particular industry sector to help the industrial units (and encourage peer to peer learning) improve the efficiency of their operations. • Facilitate exchange of energy management best practices across sectors in common areas like utilities, where there is a high possibility of replication. Dr. Ajay Mathur and Shri Somnath Bhattacharjee exchanging MoU • Facilitate sharing of information/capacity building on upcoming approaches to energy management and to new and innovative A Memorandum of Understanding (MoU) for collaboration in technological choices for promoting energy efficiency available managing and operationalizing KEP was also signed between BEE and IIP at the launch event. The MoU was signed by Dr. Ajay at the international level. Mathur on behalf of BEE and by Shri Somnath Bhattacharjee on An ‘Action Plan’ detailing the roadmap for KEP and the inaugural behalf of IIP. issue of the Quarterly Newsletter was released by the Chief Guest, Shri P. K. Sinha, Secretary, Ministry of Power, Government of India, The workshop had participation from over 450 eminent industry Shri R. N. Choubey, Special Secretary, Ministry of Power and Dr. Ajay leaders from all PAT sectors, distinguished speakers and experts Mathur, Director General, Bureau of Energy Efficiency at this launch spanning industry, energy auditors and managers, industry event. Shri Satish Kumar, Joint Secretary, Ministry of Power was also associations, government agencies, research institutions and senior Industry professionals amongst many others. present at the Launch event.
9 months on ....... Journey So Far Sector-Specific Best Practices Workshops to Promote Energy Efficiency
Aluminium Sector Best Practice exchange workshop, organized on 24th April, 2015 and hosted by Vedanta Ltd at Jharsuguda, which was attended by 200 participants.
Cement Sector Best Practice exchange workshop, organized on 23rd June, 2015 and hosted by J K White Cement at Jodhpur, which was attended by 150 participants.
Cross Sectoral- Best Practice Workshops to Promote Energy Efficiency Thermal Power Sector Best Practice exchange workshop, organized on 28thOctober, 2015 and was hosted by Dahanu Thermal Power Station, Reliance Infrastructure Limited at Dahanu (Maharashtra). The workshop was attended by 230 participants, which included 100 representatives of thermal power sector and 130 representatives of aluminium, cement, pulp & paper, fertilizer, textile and iron & steel sectors.
Pulp & Paper Sector Best Practice exchange workshop, organized on 21st August, 2015 and hosted by JK Paper Ltd at New Delhi, which was attended by 120 participants.
Textile Sector Best Practice exchange workshop, organized on 28thNovember, 2015 and hosted by Raymond Ltd. at Thane, which attended by around 150 participants.
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KEP Newsletter: KEP has initiated quarterly newsletter series and so far produced 4 newsletters containing 16 detailed case studies from Aluminium, Cement, Chlor-Alkali, Fertiliser, Pulp & Paper, Iron & Steel, Textile and Thermal Power sectors, 4 policy papers and 5 technology overviews. Friendly Energy Efficiency Exchange Visits: In order to promote cross-sectoral interaction and knowledge exchange, KEP initiated “Facilitation of friendly energy efficiency exchange visits”. Sixty plants in the 8 Sectors of PAT industry have given their consent to be a part of this initiative and the process has become operational from 1st week of October, 2015.
KEP Website Launched (www.knowledgeplatform.in)
KEP website was officially launched at the Pulp & paper sector workshop on 21st August 2015. The website has been designed to provide an entry point for energy managers, energy auditors and industry to existing sources of information on best practices and also guide the users on best technologies. The website is structured to simultaneously serve as a knowledge resource bank and a platform to host multiple discussion forums.
Sector Learning Group (SLG) KEP has constituted Sector Learning Groups (SLGs) for each of the PAT sectors with representation from Industry Association, Industry Leaders and technical experts and act as advisory group for development and implementation of sector specific strategies for KEP. The SLGs is also mandated to help KEP in expanding the network of experts and developing strategy to promote peer to peer learning, outreach and rapid uptake of best practices and new technologies within each sector.
Aluminium SLG meeting was organized on 20th June, 2015 at Bhubaneswar, where members provided guidance on the future strategy to be adopted.
Cement SLG meeting was organized on 22nd June, 2015 at Jodhpur where members agreed to support the agenda on SPL Co-processing.
Pulp & Paper SLG meeting was organized on 20th August, 2015 at New Delhi, where members agreed to support KEP initiative and provide directions from time to time.
Thermal Power SLG meeting was organized on 27th October, 2015 at Dahanu, where members felt that KEP can play an important role in facilitating policy discussions around PAT.
Textile SLG meeting was held on 27th November, 2015 at Thane., where Members appreciated the initiative undertaken by BEE and IIP and pledged their support for future activities of KEP.
Policy Roundtables on key policy and thematic issues
Policy Roundtable on “Efficient Market For ESCerts In India” was organized on 6th August, 2015 at BEE office, New Delhi, which was attended by more than 60 participants. The roundtable was successful in bringing together Industry, BEE, Power exchanges, Sectoral experts and other key stakeholders on a common platform which helped in coming out with key recommendations, that have been submitted to BEE for consideration.
Policy Roundtable on “Promoting Resource Efficiency in Textile Sector: Possibilities for South-South Cooperation” was organized on 17th September, 2015 at BEE Office, New Delhi, which was attended by Bangladesh Garment Manufacturers and Exporters Association (BGMEA), industry representatives of Indian Textile sector, DFID, BEE and IIP. The roundtable will help in expanding the network of KEP to other countries in the South-Asia region to promote the exchange of best practices.
Policy Round Table on “Promoting use of Spent Pot Liners in Cement Co-processing” was organized on 22nd September,2015 at SCOPE, New Delhi, which was successful in bringing together the Regulators, Policy makers, National & International Technology suppliers as well as senior industry representatives of Aluminium and Cement sector, so that the current issues and challenges could be discussed. Roundtable led to creation a task force to deliberate and come out with a viable strategy in future.
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