“benchmarking to accelerate energy efficiency in thermal...

© Confederation of Indian Industry

“Benchmarking to Accelerate Energy

Efficiency”


Introduction - Benchmarking

Assess our own energy performance

Formulate strategies Identify gaps & possible solution

Comparison with peers or set of standards

Monitor key parameter to maintain & sustain benefit


Types of Benchmarking

Plant Level Benchmarking

• Broadly available in most of the sector • Macro Level • Difficult to identify the opportunity • Mostly limited to major parameter like

• Heat Rate • Auxiliary Power Consumption • Specific Thermal Energy

Consumption • Specific Electrical Energy

Consumption

Sectional Benchmarking

• Practiced only by few sector • Cement

• Mini Level • Easy to identify the opportunity • Covers parameter at sectional level

• Contribution of PH fan power consumption in total specific power consumption

• Performance of Equipment (For ex. Compressor kW/cfm generated)


Cross Sectoral Learnings

Comparison of Similar Sections from different Sectors

Performance areas for evaluation and comparison

Energy Intensity

GHG Intensity

Water Intensity

Environment Intensity

Computational fluid dynamic study (CFD) well known to Power plant

Replication Potential high for cement sector

Cross Sectoral Learnings

Water Conservation from Paper

Sector

Ash handling and Fuel

Grinding from Cement

Compressed Air

optimization from

Automobile


Capacity Utilization – Thermal Power Plant

Source- CEA Executive Summary for the Month of May, 2016

Opportunity for optimum utilization of

equipments at Partial Loads


Comparison of Net Heat Rate based on Plant Capacity

0.00

500.00

1000.00

1500.00

2000.00

2500.00

3000.00

Top 3 Top 10 Identified Gap

2398.53 2531.05

132.51

Net

Hea

t R

ate

kcal

/kW

h

Net Heat Rate of Plants- 500-600 MW Capacity

0.00

500.00

1000.00

1500.00

2000.00

2500.00

Top 3 Top 10 Identified Gap

2187.04 2341.52

154.48 Net

He

at R

ate

kca

l/kW

h

Net Heat Rate of Plants- 660-800 MW Capacity

5.2%

6.6%

Source- CEA CO2 Baseline Database Version 11.0


Benchmarking of Auxiliary Power Consumption

Source- Shakti Sustainable Energy Foundation and ICF Report- Thermal Power plants in India:

Technical Opportunities for Improving Efficiency and Reducing Emissions


Sectional Benchmarking - Auxiliary Power Consumption

PARAMETERS Plant A Plant B Plant C

Installed Capacity 250 250 250 300 300 250 250

BFP Specific Power

Consumption in KW/MW 23.28 23.22 26.05 29.91 29.81 26.56 22.51

PARAMETERS UOM Plant A Plant B Plant C

Unit Capacity MW 700 700 660 660

Steam Consumption

for BFPs TPH 120 120 108 92

Steam Pressure for

BFPs Kg/cm

2 11.5 11.5 10 6.4

Steam Temperature for

BFPs Deg C 350 350 370 334

BFP, 41%

FD Fan, 15% Compressor

s, 6%

ACC fans, 16%

ID Fan, 4%

PA Fan, 2%

WTP, 1% CHP, 1%

ACWP, 4% CEP, 3%

ESP, 1% Lighting, 1% AC & Vent, 1% Misc., 4%


Benchmarking – Paper Sector

0

200

400

600

800

1000

1200

1400

1600

1800

Plant 1 Plant 2 Plant 3 Plant 4 Plant 5 Plant 6 Plant 7 Plant 8 Plant 9

1211

1511

1294

1103

1399

1547

898 922

1699

Specific Electricity Consumption (kW/T of FNP)

~25%

0

2

4

6

8

10

12

Plant 1 Plant 2 Plant 3 Plant 4 Plant 5 Plant 6 Plant 7 Plant 8 Plant 9

6.6

11.55

8.77

5.62

6.45

9.02

6.8 6.91 6.84

Specific Steam Consumption (Ton Steam/Ton FNP)

~21%


Benchmarking – Paper Sector

0

10

20

30

40

50

60

Plant 1 Plant 2 Plant 3 Plant 4 Plant 5 Plant 6 Plant 7

41 44

49 53

42 44 49

Green Energy (% of Total Energy)

~14%

0

20

40

60

80

100

Plant 1 Plant 2 Plant 3 Plant 4 Plant 5 Plant 5

42 45

82 81

69

45

Specific Water Consumption (m3/Ton of FNP)

~37%


Sectional Benchmarking – Best No. Vs Avg. No.

Best Plant Top 10 Plant

Particular kWh / T of

FNP kWh / T of FNP

Raw Material Storage, Handling & Preparation 12 290-320

Pulp Mill Section 196

Paper Machine Section (Including waste/secondary processing

& stock preparation) 539 580-620

Chemical Recovery Section 138 260-280

Water System & Treatment (Including DM & RO plant for boiler

feed water) 29

Effluent Treatment Plant 21 70-80

Other 25 82-100

Utilities (Power Plant - Boilers & TGs, Compressors) 143

Total 1100 1200-1300


Sectional Benchmarking – Best No. Vs Avg. No.

Beat Plant Top 10 Plant

Particular T of steam / T

of FNP

T of steam / T of

FNP

Raw Material Storage, Handling & Preparation - -

Pulp Mill Section 0.88 1.8-2.0

Paper Machine Section (Including waste/secondary processing &

stock preparation) 2.23 3.1-3.3

Chemical Recovery Section 1.93 3.2

Water System & Treatment (Including DM & RO plant for boiler

feed water) - Not Available

Effluent Treatment Plant - -

Other 0.07 -

Utilities (Power Plant - Boilers & TGs, Compressors) 0.44 Not Available

Total <6.0 8.0-10.0


CII - Godrej GBC – Experience in Benchmarking

Cement Sector

Felt the Need for sectional benchmarking

CII and Steering committee get involved for benchmarking

Some of the benefits at a glance

Performance evolution of top 10 plants : section wise & technology wise

Analysis & Potential areas of improvement with cost economics

Identification of case studies for bridging the gap

50 Energy Indicators – Islands of Excellence


Crusher SEC : kW / MT Material


Raw Mill SEC : kW / MT Material


Pyro Section SEC : kW / MT Material

16.2818.30

21.8023.55

10.00

15.00

20.00

25.00

30.00

Plant 1 Plant 2 Plant 3 Top 10

5 Stage Preheater


Thermal SEC: kcal/ kg Clinker


Cement Grinding SEC : kW / MT Material


Electrical Energy – Upto Clinkerisation SEC : kW / MT Clinker


Top 10 Cement Plant

Plant Thermal SEC

(kcal/kg clinker)

1 676

2 677

3 682

4 685

5 688

6 690

7 695

8 699

9 699

10 699

Plant

SEC 16-17 Product mix %

kWh/MT total Cement

PPC OPC PSC/Other

Plant 1 63.91 18 82

Plant 2 65.67 61 39

Plant 3 66.07 32 68

Plant 4 66.27 26 53 21

Plant 5 67.66 6 94

Plant 6 68.7 65 35

Plant 7 69.8 31 69

Plant 8 70.58 8 47 45

Plant 9 71.4 64 34

Plant 10 71.98 49 49 2


Benchmarking – The Way Forward

Identifying opportunities to improve energy efficiency

Understand underlying factors that impede implementation of energy efficiency measures

Increase openness and knowledge sharing

Develop performance-based energy indicators

Generate comprehensive comparison of various aspects of operations i.e., energy efficiency, equipment productivity and environmental performance

Analyse reasons for variation in performance at equipment and plant level

CII would be glad to work with Industry to work towards this.


Thank You….

25

Contact: Parag Mundada

Associate Counsellor Confederation of Indian Industry

CII – Godrej Green Business Centre Survey # 64, Kothaguda Post

R R District, Hyderabad 500081 INDIA

Direct: +91 7032666370 Email: [email protected]

Web: www.greenbusinesscentre.com / www.cii.in

mailto:[email protected]

http://www.greenbusinesscentre.com/

http://www.cii.in/

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