advanced training programme on energy management

© Confederation of Indian Industry

A Very Warm Welcome to all A Very Warm Welcome to all ……

Advanced Training Programme on Energy Management

04 December 2010, 04 December 2010, ShreeShree cement Ltd, cement Ltd, BeawarBeawar


About CII

� An Apex Industry Association � Over 8100 Member Companies� Industrial Services

�TQM�TCM�Energy�Environment�TPM�Green Buildings

� Interaction with Government on Policy Issues

� Network Offices in India & Abroad


“Centre of Excellence” for Energy, Environment, Green Buildings, Renewable energy, Water & Climate change activities in India

CII - Sohrabji Godrej Green Business Centre, Hyderabad

A unique Public – Private Partnership(CII, Govt of Andhra Pradesh, USAID and Pirojsha Godrej Foundation)


CII-Godrej GBC, Hyderabad

� First “Green” Building in India

� First “Platinum” rated building

outside USA

� First Platinum building in the

World under LEED version 2.0

(other 2 buildings are under

LEED version 1.0)

CII-Godrej GBC building has achieved 56 points out of 59 points attempted


President of India Inaugurates

14 July 2004, Hyderabad14 July 2004, Hyderabad


CII-Godrej GBC Building - Select features

� Zero water discharge� 100% waste water recycling

� 55% reduction in energy consumption (Over base model)

� 100% Day lighting

� Eco-friendly A/C plant � Non-CFC & High EER

� 20% Power - Solar PV

� 60% recycled materials

� Roof garden - 60% area

� No toxic paint and sealant

� Low VOC carpets

� Wind tower

� Minimum site disturbance


CII-Godrej GBC - Range of Services

1. World class energy efficiency

2. Green Audits

3. Water Audits

4. Facilitating Green Buildings

5. Total Cost Management

6. Renewable Energy Services

7. Technology Centre

8. Training programmes � Energy, Water, ISO, OHSAS, Green

Buildings, TCM

9. Conferences and Seminars


� Team of experienced engineers

� Energy, Environment, Water

� Sectoral strengths

� Automobile & Engg, Cement, Chemical, Fertilizer, Pharma,

Pulp & Paper, Power, etc

� Latest instruments – almost all major parameters

� Energy, Water, Air

� Access to international service organizations/experts

� USAID, CIDA, WRI

� Databank

Facilities with CII-Godrej GBC


Publications

�Publications for awareness creation � Energy Publications – Widely accepted by industry

� Manual on Specific Energy Consumption Norms

� Manual on Energy Efficiency at Design Stage

� Manual on Energy Efficiency in Pumping Systems

� Manual & CD on Variable Speed Drives

� Manual on best practices in Cement, Pulp & Paper, Power, etc

� Training programmes on Energy

� Centre-wise and In-house

� Environment

� Green business directory

� Booklet on Industrial Best Practices

� Water

� Booklet on industrial best practices


Achievements

1100 detailed audits conducted

Rs.2100 Million annual recurring savings

achieved


Achievements

Recipient of

“Best Energy Auditor Award”

For

Five successive years

instituted by PCRA, Govt. of India


Why Energy Conservation?Why Energy Conservation?


Indian Energy Scenario. . .

13,242 MW RES

4,120 MWNuclear

36,877 MWHydro

95,151 MWThermal

1,49,390 MW Installed Capacity

� Energy Shortage ~ 7%

� Peak Demand shortage ~ 12%

As on May 2009, Source : Ministry of Power


Indian Energy Scenario. . .

� To meet demand supply gap & Achieve

targeted GDP

� Capacity addition – 1,00,000 MW in next

10 Years

>3- Fold increase in Last 12 Years

Power Cost Increase

151179

207226

254282

315347

375

418 422441

474

0

100

200

300

400

500

6001991

1992

1993

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

Year

Ps/k

Wh


Comparison of Power Cost

4.74

1.8

1.20.8

1.7

0

1

2

3

4

5

6

India USA China Saudi

Arabia

Europe

Rs. / kW

h


Competitiveness of Cement Industry

Indian Cement Industry

� World best SEC : 65 – 70 Units/Ton

� More Energy Efficient than European & American Plants

Rs.220/-< 110S E Asia

Rs.204/- to 216/-< 120 USA & Europe

Rs.418/-< 90India

Power Cost / Ton of Cement

Average SEC


How cement industry has reduced SEC?

� No external/ government pressure

� Tremendous competition

� Combination of internal efforts, external

assistance, suppliers etc.,

� A few units have gone ahead

� “In search of excellence” in energy management

� Sharing of knowledge amongst various units

� Several fora

Excellent example for other industries


CII & Cement Industry

� Energy Audits in more than 75 cement units

� ACC - Kymore, Madukkarai, Lakheri, Tikaria, Sindri, Wadi,

Gagal & Bargarh

� Ultratech - Tadipatri, Awarpur, Rajula

� Lafarge – Arasmeta, Jojobera

� B K Birla - Kesoram, Vasavadatta, Mangalam Cement

� Century Group - Century Cement, Maihar & Manikgarh

� Ambuja Cements – Kodinar, Eastern, Rajasthan, Maratha

� Grasim – South, Vikram,Aditya

� Madras Cements – Alathiyur, RR Nagar, J Puram

� Shree Cement, Jaypee, Chettinad, Dalmia, JK White, JK

Lakshmi, Malabar, My Home, India Cements, etc..


CII & Indian Cement Industry

� Close association � World Class Energy Efficiency

� GHG emission inventorization

� Specific energy consumption norms for

Indian cement industry (1998 & 2006)

� Promotion of WHR systems

� Policy discussions to increase Waste Fuel

utilization

� Training programs, Conferences, etc


World Class Energy Efficiency


What is the Opposite of Best ?

• Bad

• Average

Answer : Good


Good Vs. Best (World class) units

• Both appear same

• Awareness level –high

• Significant energy

saving achieved

“World class energy efficient” units are

unique & different


Bench marking & Trend setting

Good Vs. World class

�Follow bench marks � Set Trends &

Others follow


Information sharingGood Vs. World class

� National & Global level

� Coca Cola, Philips

� Share within

� Operate in isolation


Implementation of Latest technologies

� Pioneers in implementation

� Capacity to take risk at organization level

� Technology developer’s firstpreference

� Want proven technologies

� Need Case studies before

implementation


Monitoring & Energy Scorecard

Good Vs. World class

� Monitoring

� Excellent data

generation

� Energy score card


Encon activityGood Vs. World class

� Driven by external

factors

� Energy cost increase

� Mandatory audit

� On going activity

� Top management

committed to Encon

� Resource allocation


World Class Energy Efficient Unit

� Trend setter in Norms – Lowest in world (Units/ton)

� Leader in implementing Latest Technologies

� Energy Efficiency

� Waste Heat Recovery

� Waste Fuel Utilization

� Energy Wastage – Nil

� Energy Scorecard

� ENCON “On-going activity” – Management system


World Class Energy Efficiency in Cement Industry

� To facilitate emergence of 5 “World Class Energy

Efficient units” in India

� Chairman – Mr G Jayaraman, Executive

President, Birla Corporation Ltd

� Working closely with 6 cement units over last 4

years


World Class Energy Efficiency� Activities carried out so far

� Phase 1 activities in 6 cement plants

� Energy Training Program

� Detailed Energy Audits

� Visit among participating companies

� International Best Practices Mission

(Europe, UK & Japan)

� Experiences documented & manuals

released


World Class Energy Efficiency� Tangible benefits of activities carried out so far ..

� Dalmia Cements Ltd, Dalmiapuram - Rs. 220 Lakhs

� Madras Cements Ltd, Alathiyur - Rs. 150 Lakhs

� Maratha Cement Works, Chandrapur - Rs. 210 Lakhs

� Shree Cement Ltd, Beawar - Rs. 360 Lakhs

� Ultratech Cement Ltd, Tadipatri - Rs. 160 Lakhs

� Vasavadatta Cement, Sedam - Rs. 140 Lakhs

� Other benefits

� Sharing of information

� Learning best practices from other plants – nationally and

internationally

� Extensive training for plant team


World Class Energy Efficiency

� Activities : Phase 2

� Energy Score card

� Further improvements in energy efficiency

� Additional Training on Energy Management

� Energy audit surveys

� Sharing best practices

� Visit to international cement plants to adopt latest

technologies

� Focus on implementation of projects identified

� Experiences documentation & manual release

� Additional 4 plants for phase 1 activities


Agenda

�Modules on

� Energy Audit

Methodology

� Fans & Blowers

� Ball mills

� Kiln, Cooler &

Preheater

� Air compressors

�Modules on …

� Motors

� Electrical

distribution

� VSD & Harmonics

� Lighting

� GHG Inventorisation


Energy Audit Methodology


A few learningsA few learnings……


Two Examples from Sports…

� Sergei Bubka - Ukranian pole vaulter� I person to cross 6-m mark

� Continuously improved

� Broke his own records > 14 times!

Efficiency Improvement - Continuous


Olympic Gold Medal Winners in High Jump

2.6

2.4

2.2

2

1.8

1.6

1900 1920 1940 1960 1980

Scissors

Western Roll

Straddle

FosburyFlip

Source: Pascale


Adopt the latest technology

Two Examples from Sports…

� Dick Fosbury

� Basically a Gymnast

� Applied principles of gymnastics to high jump

� Result – A quantum jump!

Inputs from Other Industries - Innovation


Energy Conservation at Macro Level

Measure of EnConactivities

Reduction in specific energy consumption


Energy conservation at macro level …

Three-pronged approach

Capacity utilisation

Fine-tuning

Technology upgradation


Excellent companies

have tapped all three opportunities

3 separate teams withcommon objective

Energy conservation at macro level …


Energy Audit Methodology

Systematic approach

Ask questions like:

� What?

� When?

� Why?

� Where?


Macro Level - Methodology

Any process/unit operation

Energy input (a)

TheoreticalRequirement (b)

Unavoidable losses

(c)

(d)Avoidaablelosses

a = b + c + d


Focus should be

� To concentrate on avoidable losses

� Quantify the losses

� Identify ways and means for

reduction

� Implementation

Macro Level - Methodology …

NEED OF THE HOUR

ACTION!!

advanced training programme on energy management

Documents