(3) overview of energy auditing in process industry …...overview of energy auditing in process...
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Overview of Energy Auditing in Process Industry – The Indian Experience By
Dr. G C Datta RoyDSCL ENERGY SERVICES Co Ltd2nd Floor, Kanchenjunga Building18, Barakhamba RoadNew Delhi – 110001India+91 11 [email protected]
Presentation StructureAbout DSCL Energy ServicesChemical Industry -OverviewEnergy CostEnergy Efficiency MarketApproach to EE DiagnosticsConclusion
DSCL : Business Portfolio
$750 MN Conglomerate
•Fertiliser
•Agri-Marketing
•Sugar
MANUFACTURING PLATFORM
Agri-Retail
Haryali Kisan Bazaar
ENERGY SERVICES
1999
SERVICE PLATFORM
AGRI BUSINESS PLASTICS CHEMICALS
Commodity
Speciality
Commodity
Speciality/ Value Added
Power (>230 MW) ( RE >70 MW) (Export >25 MW)
Fenesta
U PVC Window system
DSCL Energy Services-Service Offerings
Service Offerings
Energy Efficiency
Renewable Energy
Fee Based Engineering and Project Management
Engg. & Project Mgmtunder SharedSavings
(EPSS)
Engineering, Procurement & Construction (EPC)
Perf. Measurement& Verification (PMV)
Design improvement
Energy Diagnostic Study (Audit)
Feasibility Study
Owner/ Lender Engg.Services
Knowledge Management
Energy Strategy & Management
Project Management Portfolio Consulting Portfolio
Our Credo:Our Credo:“Development of Partnership for “Development of Partnership for
Progress Together byProgress Together byDelivery of Tangible & Delivery of Tangible &
Measurable EnergyMeasurable EnergyPerformances”Performances”
Recipient of
BEST ENERGY SERVICES COMPANY AWARD
For four Years
(2001- 02, 02-03 , 03-04 & 05-06)
From PCRA, MoP&NG
DSCL ES-Business Portfolio
Energy Efficiency & ESCO Performance Contracts Green Building Commissioning ServicesRenewable EnergyDistributed Energy SystemCDMInternational Consulting-Alternate Energy Development
Process Industry - OverviewOne of the fastest growing sectors of Indian EconomyContributes to 13 % of GDPThe industry is fragmented and dispersed –multi product and multi faceted
Process Industry – Overview contd..
Broad market segmentsBasic Inorganic and Organic Chemical Drugs & PharmaceuticalsPesticides & AgrochemicalsPetrochemicalsFertilisersDyes & PigmentsFine & Speciality Chemicals
Energy Cost Ranges- Select Industries
Based on CMIE database
Energy Prices-Trend
Rs per ton of coalRs Per kL of fuel oil
Continued escalation of energy price seems to be economic reality.
Only way to reduce cost is by improving energy efficiency
0
5000
10000
15000
20000
Rs/
Uni
t
1975 1980 1985 1990 1995 2002 2007
Price Trends in Coal and Fuel Oil
Energy CostEnergy Cost as % of Total Production Cost
0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
50%
Energy Cost as % of Total Production Cost
0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
Petrochemicals
Other Organic Chemicals
Average – 9%20% of the plants have their energy cost in the range of 10% to 20%
Average – 9%38% of the plants have their energy cost in the range of 10% to 30%
Energy Cost as % of Production Cost
Energy Cost – contd..
Energy Cost as % of Total Production Cost
0%
10%
20%
30%
40%
50%
60%
70%Caustic SodaAverage - 44%45% of the plants have their energy cost falling in the range of 40% to 60% Nitrogenous Fertilisers
Average - 22%50 % of the plants have their energy cost falling in the range of 20% to 30%
Other FertilisersAverage - 6%35% of the plants have their energy cost falling in the range of 5% to 15%
Summarising
Nitrogenous Fertilisers 13% to 37%Refinery 1% to 8%Caustic Soda 14% to 62%Petrochemicals 1% to 48%Drugs & Pharmaceuticals 1% to 31%Other Organic Chemicals 1% to 40%Other Fertilisers 1% to 20%
Market Segment Variation% Energy Cost
Many reasons for wide variation nature of finished product,
price of input energy,process technology,
equipment technologyoperation & maintenance practices.
It is therefore, a significant challenge to estimate the EE market based on benchmark analysis.
An alternate methodology has been developed for the same
EE Investment Market-Process Industries
EE – Projects TypeGeneric Energy Efficiency Projects
Water & Process pumpingFans, Blowers, CompressorsPiping Boiler & Turbine efficiency improvement Efficienct Lighting Rationalising distribution systemMetering and accountingFuel substitution
Process Specific Energy Efficiency Projects
Process upgradationProcess synthesis/integrationSynthesis of control systemWaste heat recovery/HEN
Major equipment replacementCogeneration/CHPAutomation Load optimization
Sample Projects (Generic)-DSCLES Audit
SN Project Savings, mn Rs
Investment, mn Rs
1 CT pump Eff Improvement 7.78 2.80 2 Blowers 1.80 0.10 3 Compressor System 1.30 0.80 4 Spent wash pumping system 0.52 0.35 5 Lighting 2.00 1.60 6 Raw Water Pumps 0.90 0.40 7 Coal based thermic fluid heater 7.00 14.00 8 Electrical Distribution 0.03 0.05 9 Boiler Excess air control 1.20 0.90
10 Conversion of PRDS energy to power 5.50 5.80 11 Boiler Auxiliaries 1.40 1.81 12 CT Fans 1.50 2.00
Simple payback ranges from few days to 2 years
Sample Projects (Process)SN Project Industry Savings,
mn RsInvestment,
mn Rs1 Technology Upgradation - Diaphragm to Membrane Caustic Soda 34.25 143.86 2 Use of Hot caustic lye as feed Caustic Soda 0.17 0.12 3 Conversion of mesh type to strip type anodes Caustic Soda 9.50 21.45 4 Pre-concentrator & pre-decomposer Nitrogenous Fert. 126.00 439.60 5 High performance trays Nitrogenous Fert. 42.00 58.44 6 Retrofits upgradation of measuring & control instruments Petrochemicals 9.84 28.40
Payback ranges from a year to about 5 years
Energy Efficiency Improvement - Market Potential
Source : ADB EETA : 3885 – IND
EE Investments,
mn Rs
Savings, mn Rs
EE Investments,
mn Rs
Savings, mn Rs
Nitrogenous fertilisers 2,930.00 1,040.00 4,485.00 1,515.00 Refinery 3,720.00 970.00 4,360.00 1,130.00 Caustic soda 630.00 920.00 1,390.00 365.00 Petro Chemicals 4,930.00 1,930.00 7,605.00 3,110.00 Drugs & pharmaceuticals 220.00 660.00 115.00 200.00 Other Organic Chemicals 400.00 640.00 NA NAOther Fertilisers 1,125.00 400.00 1,720.00 580.00
Market Segments
Generic EE Projects Process EE Projects
Energy Saving Potential:850 MW
Energy Efficiency Improvement - Market Attractiveness
Other Fertilisers
Nitrogenous fertilisers
Refinery
Caustic soda
Drugs & pharmaceuticals
Petro Chemicals
Other Organic Chemicals
Financial Attractiveness
Mar
ket A
ttrac
tiven
ess
L M H
H
M
L
Petro Chemicals
Other Fertilisers
Nitrogenous fertilisers
RefineryCaustic soda
Drugs & pharmaceuticals
Financial Attractiveness
Mar
ket A
ttrac
tiven
ess
L M H
H
M
L
Generic Energy Efficiency Projects
Process Specific Energy Efficiency Projects
Energy Audit – Different Approaches
Traditional Energy Audit – Technology Driven & Event OrientationTarget Cost Reduction – Business Process Driven & Market OrientationBenchmark – Goal & Strategic OrientationFundamental – Innovation & Leadership
Case example-traditional audit
10242436--10
036--100
Cooling tower layout optimization9.
105.3
5.36.3--196.3--19Bigger high efficient
raw Water supply pumps to RO Plant
12
8101016--4416--44Chilled water
distribution system10
121212123745-123745-Condensate recovery
schemes11
125.4
5.45.3--195.3--19Main CT Fans - Power
Consumption Optimization
14
12
6.25
6.256.25520-6.25520-
Flash steam recovery from the flash tank in
the Dextrose Plant
13
Months
Possible
Most Likely
Rs. Lacs
CM/day
Kg/hr
kW
Rs. Lacs
CM/day
Kg/hr
kW
Most Likely SavingsMost Likely Savings PaybPaybackack
Investment Investment (Rs. Lacs)(Rs. Lacs)
Possible SavingsPossible Savings
List of Energy Saving List of Energy Saving MeasuresMeasures
Measures of Greater than 6 but less than 12 months Payback
Pros & Cons-Traditional Audit
Sub-optimal assessment of savings potentialGenerally not linked
to the company’s P&L accountDifficult to attract top
management attention
Good for the auditors-possible to accurately assess level of effortsQuick identification of
low hanging fruitsLow cost
ConsPros
Investment Oriented: (ESP with> 1 yr PB)
Rs. 25.88 Mn/Yr (7%)Investment:Rs 47.07 Mn.
Modifications Oriented:(ESP with< 1 yr PB)
Rs 36.29 Mn/Yr (9.8%)Investment: Rs 10.85 Mn
Operational Improvement
(ESP withNil Investment)
Rs 8.65 Mn/Yr (2.33%)
Rs.
370
Mn/
YrR
s.37
0 M
n/Yr
Rs.
290
.4 M
n/Yr
Rs.
290
.4 M
n/Yr
Rs.
70.4
Mn/
YrR
s.70
.4 M
n/Yr
(19
%)
(19
%)
6.60TS Lighting
Mn Rs/YrAreas
1.56Material handling
0. 49C & C Voltage reduction
2.95Evaporator
0.63Material handling
7.48Process chemicals
6.63Other machines
11.93Pumping system efficiency
1.29Cogeneration
5.38Fans & compressors
1.91Lighting
2.21Caustic & Chlorine system
10.89Utility
10.67Cogeneration
PresentPresentEnergy billEnergy bill
Energy BillEnergy BillAfter ESPAfter ESP
Case example-cost reduction targeted audit
Target-20%
Advanced audit-Pros & Cons
High costComplex investigation
process-Longer time frame-Difficult to pre-assess
audit cost-Difficult to sell to line
managersLimited availability of
qualified & experienced auditorsRestriction from
technology licensors
Maximizing savingsEstablished strong
baseline & M&V methodologyLinkable to P&L
accountEasy to sell to top
management
ConsPros
Continuous PanCondenser
Condenser
Centrifugals
Boiler
Captive consumptionTo Grid
Alternator
Turbine
Condenser
Batch Pan
Spray Pond
Quintuple Effect Evaporator
Evaporators-Vapor Bleeding for juice heating Multiple effect evaporators with vapor cells High efficiency evaporators - falling/rising film
Variable Frequency Drive
Fibrizers Drive
Bagasse Carrier
Cane Conveying System
Fibrizer
Hydraulic Drives - upto 20% lesser power as compared to turbo-drives Bagasse Moisture control/ sensor/ automation from 50-55% to 47-50%Macerator - better imbibation efficiency - reduction of evaporator load (10-20% on fibre)
Cane Conveying Feed Control System
Pan High efficiency vacuum pumps - 20% saving High efficiency water pumps - 30% saving Low water condensor Cascade Pan boilingMechanisation - Pan boiling - continuous pan
Centrifugals:High efficiency centrifugal machines - power saving
Condensers:Recovery and appropriate use ofcondensate Condenser
Hydraulic Drives
Mills
Cogeneration Bagasse drier - reduction in moisture by 4-5%High Efficiency ID Fan High Pressure boilersHigh efficiency turbines
Minimum Energy design-Sugar
Minimum process steam need is about 30%against
current value of over 45%
25
Strategic Encon Plan
AWARENESS
MEASUREMENT
ACCOUNTING
NORMAL AUDIT
MASS BALAN
CE
PROCESS SYN./HEN EXERGY BAL.
HEA
T BA
LAN
CE
0
GAP ANALYSIS
ACTUAL CO
NSU
MPTI O
N
IDENTIFICATION OF LOSSES
THEO
RET
ICAL
NEE
D
MAINTENANCE UPGRADATION
TRAN
SMISSIO
N
EFFICIENCY
UTILISATION EFF./ WASTE HEAT RECOVERY
GEN
ERAT
ION
EFF
ICIE
NCY
CAPITAL PROJECTS
EQU
IPMEN
T UPG
RAD
ATION
INSTRUMENTATION / CONTROL AUTOMATION
PRO
CESS
REV
IEW
RESEARCH &TECHNOLOGY DEVELOPMENTPR
OD
UCT SU
BSTITUTIO
N
LONG TERM ENON. PLAN
PILO
T PR
OJE
CT
Sour
ce :
Dr G
C D
atta
Roy
, PhD
The
ses
Designing the audit process
Utility EnergySavings
Co-generationSystem /
Energy System Integration
Process EnergySavings
IndustryTechnology
R & D
Pumping System, Fans,Boilers, HVAC, Steam SystemElectrical System, Compressors
Process synthesisSynthesis of HENSynthesis of control system
Innovation
Long term cost reduction goal
Approach to match financial & organizational capacity
Macro Approach – Implementation of Energy Cost Reduction Projects
•Assessment of measurement system •Validation of benchmark audit
Walk Through
Audit
Benchmark Audit
Investment Audit/Minen design
Project Development
Project Implement
-ation
Operation &
Maint.
Audit based on client's data
•Data Collection & Analysis •Macro assessment of Savings Potential •Investment need assessment •Project Selection for investment grade evaluation
Investment Grade Evaluation•Concept Design •Basic Engineering •Technical constraint feasibility analysis •Cost-benefit analysis •Project Prioritization•Management Presentation
•Baseline Establishment•Measurement & Verification System•Detailed Project Report* •Financial Advisory Service*•Procurement Assistance•Project Management •Measurement & Verification•Management Information System•Training* Service provided if project-financing assistance is required
•Sustenance Support•Operation & Maintenance
ConclusionProcess industry is energy intensive and energy cost reduction would remain one of the key strategy for global competitivenessSuch cost reduction has to be achieved primarily by energy efficiency improvementDifferent approaches for audit-project & technology based to strategic cost driven processApproach to match the present capacity of the organization to implementIt is important to link audit findings to the implementation-baseline & M&V approach