ENERGY

EFFICIENCY

PRACTICES IN

VARIOUS SECTORS

Energy Services (P) Ltd.

Background

PGS ENERGY SERVICES PVT. LTD established in 1997 as Accredited Energy Audit firm &

ESCO for various energy efficiency/conservation projects of Industry, Commercial buildings

& MCs. Our areas of expertise includes a broad spectrum of consultancy & Implementation

of EC projects. PGSEPL is also registered as Micro Small & Medium Enterprise with NSIC

Empanelment : BEE UNDP EESL SIDBI PEDA HAREDA GEDA MEDA H.P SDA Odisha SDA ASDA AAI DRDO Chandigarh Admin

PAT : Since 2007 Cement, Textile, Iron & Steel, Chlor-Alkali, TPP, Pulp & Paper, Fertilizer EAs : BEE|EESL|NESTLE|HAFED|AAI|PEDA|SDAs|HOSPITALS|HOTEL 2009 : Successfully Implemented 1st LED Street light project in India Jan Marg, Chd & Majitha PB IGEAs & ESCO : Chandigarh Administration |SDAs| RENEWABLE : Solar Projects|Punjab & Haryana Raj Bhawan| Judicial academy Chd |Pb. Civil Sectt.| Haryana assembly, U.T – Sectt. Chd.

Cement

ACC Limited

Ambuja Cements ltd, Ropar

Ambuja Cements ltd, Darlaghat

Birla Corporation ltd

HeidelbergCements India Ltd

JK cement Works

Chanderia Cement Works

Paper & Pulp

Satia Industries Ltd

BILT Papers Ltd

Bindals Papers Mills Ltd

Yash Papers Ltd

Ruchira Papers ltd

Dev Priya Products Ltd

Naini Tissues Ltd

Shree Shyam Paper Mills

Textile:

Vardhman Group

Winsome Yarns Ltd.

Reliance Industries Limited

Grasim Industries

Arvind Ltd.

Birla Century

Ashima Ltd. Spin fab

Ashima Ltd. Denim

Hisar Spinning Mills

Soma Textiles & Industries

Rainbow Denim Ltd.

Suzuki Synthetics Pvt. Ltd

Suzuki Suitings Ltd.

Shree Rajasthan Syntax Ltd.

BMD Pvt. Ltd.

Fertilizers

IFFCO, Gujarat

IFFCO, Odisha

FACT, Kerela

SPIC, Tamil Nadu

Madras Fertilizers ltd

GSFC, Sikka

GSFC, Vadodara

GNFC, Gujarat

Mangalore Chemicals & Fertilizers Ltd.

Rashtriya Chemicals Ltd.

Paradeep Phosphates ltd

SIEL Chemical Complex

Tata Chemicals ltd

National Fertilizers ltd

Coromandel International Ltd. Vizag

Coromandel International Ltd. Tamil Nadu

Deepak Fertilizer & Petrochemicals Corpn. Ltd

.

Kanpur Fertilizers & Cement Ltd.

Zuari Agro Chemicals ltd

Iron & Steel

Anjani Steels ltd

Singhal Enterprises ltd

Top Worth Iron & Steel

Crest Steel & Power

Thermal Power plant

Yamunanagar TPP

Panipat TPP

NTPC Ltd.

Contents 1. Case Study: Pulp & Paper Sector Strategies for EE & ENCON Approaches

2. Case Study: Cement Sector EE with zero investment

3. Case Study: Building EE project ESCO project

4. Case Study: Iron & Steel Sector Optimization Strategies for EE

Case Study: PULP & PAPER INDS.

Satia Paper Mills, Muktsar (Punjab)

Energy Efficiency strategies adopted: Achievements Quantified

1. Modification in Paper machine (press and wire part) 3350 Mtoe

a. Steam saved = 9900 tonne (annual) ~ 10% 936 Mtoe

b. Fuel saved = 2600 tonne/yr

c. Dryness = 3% increase

d. Production = 6 tonne/day increase~1980T/yr 1736 Mtoe

e. M/c Speed = 50 rpm increase ~ 51% of more

Press part modification for enhanced water removal Hydronip, Hydraulic pistons

Press Roller Change

Contt……….

Energy Efficiency strategies adopted: Achievements Quantified

2. Modifications in Vaccum pumps 29.455 mtoe

a. Header modifications 100 kW

b. Pump/ Motors replacements 345 kW

c. Shutting OFF 3 vaccum pumps (usage = 1 pump)

8.6 mtoe

3. Commissioning of H.P Boiler (490°C)

a. increase in evaporation ratio = 3.8 to 3.9 t/t

b. fuel saved = 3.16 % ~ 4189 tonne/yr

Total savings 1508.22 mtoe

Case Study: PULP & PAPER INDS.

Ruchira Paper Mills

ENCON Approach Benefits/ savings

1. Close loop arrangement for bucket elevator Rs. 7.5 lacs energy cost/yr

BENEFITS:

a. Furnace efficiency improvement 0.14%

b. ID Fan load reduction 84 KWH per day

c. Steam saved 39 tonne per day

d. Manual labour cost cutting Rs. 8000 monthly

e. Fuel saved 0.5 tonne per day

ENERGY SAVINGS 2.6MTOE

Contt………..

ENCON Approach (Year 2016) Benefits/ savings

2. Heat Exchanger (3 no.s) ~ Black liquor Rs. 2.94 crores~year 1

a. Temp recovered 85° C

b. RO water temp increase 35 °C

c. Steam saved 80 tonne/day

d. Total savings 6.96 MTOE

Initial and present scenario comparison

Energy Consumption before Heat exchanger 1197980 mkcal

Energy Consumption after Heat exchanger 1179764 mkcal

SAVINGS 18216 mkal

Case Study: Cement Sector

Ambuja Cement, Ropar (Punjab)

Energy Conservation measures Savings Achieved

Increase of biomass usage in place of coal (16 % to 40%) 43,461 mtoe

a. Optimisation of excess air in boilers (33% to 30%) 3083 mkcal

b. Improvisation in CHP, saving in electrical power f for coal crushing & Grinding

984 mkcal

c. Sensible heat savings due to lower flyash (3965 tonne ash) 3230 mkcal

Installation of sonic soot blower~dislodging ash deposit 30,521 mtoe

a. Energy savings 6985.2 mkcal

b. Decrease in fuel consumption 2% approx.

Contt….

Energy Conservation measures Savings Achieved

Bottom Ash draining via bed ash cooling ~ recoversensible heat from hot bed material

92,020 mtoe

a. heat loss savings in bottom ash (coal) 133 kcal/kg coal

b. heat loss savings in bottom ash (biomass) 45 kcal/kg biomass

Improvisation in packing plant/ interlocking in bucket elevator

54747 mtoe Rs. 1.33 crores

a. Increase in production 11 MT/hr

b. Reduction in electrical power consumption 1663447.26 kWh

c. Reduction in running hours 3473 + 2609 Hrs.

Improvement = arresting air leakages + stopping the idle running during shift change +extraction blockage cleaned in silo

Case Study: Cement Sector

Diamond Cement Ltd. HCIL, Damoh

Energy Conservation measure adopted Energy Savings

1. Installation of WHR System 1,01,146 mtoe

Benefit:

a. Recovery of waste heat from 3 kilns 250-300°C Recovered

b. Energy Savings 118.80 Mio kWh

c. Annual Cost savings Rs. 784 millions

Investment Rs. 1890 millions

Payback 2.4 years

ESCO Project

As part of an initiative to reduce energy cost and consumption, SDA secured the services of PGS Team to

perform an energy audit and prepare a detailed project report of Office Building in an effort to develop com

prehensive Energy Conservation and Retrofit Measures (ECRMs).

Case Study: Building

Previous Present

Type Annual Energy consumption (kWh) Type Annual Energy consumption (kWh)

T-12 Double Fixture 10108.80 20 W*2 LED Tube Light 3888.00

T-12 Single Fixture 2920.32 20 W LED Tube Light 1123.20

Old Ceiling Fan 2395.00 BEE five Star Rated Ceiling Fan 1530.00

Old 1.5TR Split AC 33364.80 BEE five Star Rated 1.5 TR Split AC 26092.8

Total 48788.92 Total 32634

Previous & Present Annual Energy Consumption Scenario

Case Study: Office Building

Energy Savings in terms of MTOE & Avoided Capacity Generation

As a result of implementation of the aforementioned ECRMs, the state would be able to avoid a

capacity addition (MW) to cater this reduction of load. This is calculated in terms of Avoided

Capacity Generation (MW) using the formula given below:

• Total Annual Energy Savings : 16,055 kWh

• Avoided Capacity Generation for SDA Building (in MW) = 0.0145 MW

• MTOE savings = 1.38

Impacts on reduction of Green House Gases (GHGs)- 13.17 Co2 equivalent

Case Study: Steel Industry

Singhal Entreprises Ltd.

Energy Efficiency strategies adopted: Achievements Quantified

1. Reduction of LOI content Rs. 89.84 lakhs

Benefits:

a. Unburnt Carbon loss reduction in ash 4.97 to 3 %

b. Reduction in coal consumption 3 %

c. Improvement in boiler efficiency 3-4 %

Technology used~air velocity, uniform raw material size

2. Reduction in bends~steam line to header Rs. 84 lakhs

a. Reduction in pressure drop 4 kg/cm2

b. Fuel savings 3%

Case Study: Steel Industry

Anjani Steels Ltd.

Optimization techniques for EE Savings Quantised

1. De-staging of Boiler Feed Pump 158400Kwh Rs. 9.5 Lakhs

Removing one stage (From 11 to 10 no.) ~ Discharge Pressure reduction by 6 kg/cm2 (90Kg/cm2 to 84Kg/cm2 )

20kWh

Investment of 1 lac Payback=1 month

2. Rectifying & Repairing the Leakages at SMS Compressor 144000Kwh Rs. 5.04 Lakhs

a. Power saving 1 kWh per leakage

b. Zero investment Immediate payback

Contt…

Optimization techniques for EE Savings Quantised

3. Improvement in Economizer & Air Preheater Efficiency by Cleaning the Tubes & Plugging the Leakages

Rs. 1.497 Crores

a. Heat loss saving due to air ingress

b. Coal consumption reduction (3744 tonne) 5 %

No investment Payback= Immediate

4. Reducing the Unload Set Point Pressure at Rolling Mill Compressor

60480kWh Rs. 3.62 Lakhs

a. Power Savings 12 kWh

b. Pressure reduction (8Kg/cm2 to 7.5Kg/cm2)

No investment Payback= Immediate

Our Clients…

Behaviour Presentation.pps