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ESCO MODULE for Thermal Energy Conservation

Y.D.Chavan.Opel Energy Systems Pvt .Ltd.Pune.

What is ESCO ?

The Company/ Orga nization which identifies and evaluates energy saving potentials in the process industrial unit or util ities by using their expertise and recommends the project for imp rovements in the existing system which wil l pay for itself t hroug h the savings out of it.

WHY ESCO ?n Few Facts….n Every body wants to sav e ener gy but don’t know how to start.n There is huge potential for energy conserv ation in pr ocess

industry but top management and dec ision mak ing author ities are not giv ing priorities for this activity.

n Existing engineering / maintenance staff don’t have time to concentrate for energy conserv ation act ivities.

n In many industries there is no separate Enc on team or ener gy managers ar e appointed with some tar get for ener gy conserv ation.

n Always E ncon is cons ider ed as a second priority by managem ent and does n’t wants to invest in E nergy conserv ation pro jects.

n There are always some incent ive schemes for the staff increasing production but what about those who ar e trying to save energy for com pany and u ltimate ly for Nation…

Objectives for Esco -n To Conserve Energy for Nation through Energy

Conservation Projects in Industry with simple cost effective ideas.

n ESCO should not only suggest Encon projects but they should execute the Encon projects from concepts to commissioning basis with performance guarantee.

How to start Esco Project-1.Esco should first conduct walk through Energy

audit.2.The list of Encon potentials should be given to the

Client with -*the equipment required*cost of the equipment / modification*possible savings out of the project.*pay back period for the investment.

2 5 8.006 6 7.00TOTAL-

036 0 .0 03 0 0.00So lid fu el fired HWG.So lid fu el fired Ho t water g en erato r in stead o f F .O.( CONCIDERING 3 0 0 0 ITS F .O.CONSUMPTION.)

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363 0 .0 01 0 .0 0So lar S team Plan tSo lar S team Gen eratio n P lan t fo r can teen Waste.

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0 52 2 .0 05 5 .0 0WHRS5 Ton .

Ex o -g as Heat reco v eryHo t water g en erato r.

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0 63 2 .0 06 4WHRS 3 To n2 No s

Ex o -g as Heat Reco v eryHo t water Gen erato r.

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0 21 2 .0 09 0 .0 0F.O. Sy stem 4 No s

F.O. Con serv ation Sy stems fo r Ho t Water Gen erato rs

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0 73 0 .0 05 6 .0 0WHRS 1 No .

Waste Heat Re co v ery o n 5 To n Fu rn ace.

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0 84 0 .0 05 8 .8 0WHRS2 No s.

Waste Heat Re co v eryo n 3 To n Fu rn ace

2

1 03 2 .0 03 3 .6 0WHRS2 No s.

Waste Heat Re co v ery o n 2 Ton Fu rn ace

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Pay b ack p erio d(Mo n th s)

Pro ject Co st(Rs.In Lacs)

An n u al Sav ing s.( Rs.In Lacs)

Eq u ip men t Req uired Pro ject Descrip tio n S .No

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3.After getting this list client should decide the priority for the project to be implemented through ESCO.

4. ESCO should submit detailed offer for this project with performance guarantee in terms of energy saving figures.

5. Payment terms/contract should be finalized on paper with mutual understanding .

6. ESCO will design, manufacture, install and commission the project within committed period.

How to start Esco Project- While Implementing ESCO Project-1. ESCO should take care of the existing

sy stem/equipment while designing and installing the Encon modifications.

2. ESCO will have to take care of environment while retrofitting for the energy conservation.

3. Project should be completed jointly , the end user will have to support ESCO during project execution.

4. Project should be completed committed period without disturbing the production.

Responsibility of ESCOThe project installed by ESCO should meet or exceed the savings committed to Client. Responsibility of CLIENT.Client should honor the repayment terms committed to ESCO.

Salient Features of ESCO module..

1. There is no investment by client.2. Esco to identify encon project to replace / modify

existing inefficient system.3. Design,manufacturing,installation and

commissioning is ESCO’S scope during contract period.

4. Contract period can de decided mutually by client and ESCO.

5. Energy sa ving is shared between Esco and client depending upon the reco very.

6. Esco recovers the project cost with interest and overhe ads out of the ene rgy sa vings.

Few of the examples for ENCON projects which can be implemented on ESCO basis.n Conversion of electrical heating systems/equipments to

fuel firing which may save up to 40% of cost.

n Conversion of liquid fuel fired thermal equipments to solid fuel firing , saves up to 40 % of energy cost.

n Coating from inner side or insulating from outer surfaces of the furnaces, ovens, kilns can save up to 10% of the energy.

n Furnace oil Emusification Projects can save up to 10 % of Fuel.

Few of the examples for ENCON projects which can be implemented on ESCO basis.n Waste heat recovery syst ems on D.G.Sets, Furnaces,

Ovens can save up to 30 % of Energy cost.

n Airpreheaters/ Economizers of Boilers can save 5% of fuel.

n Airpreheaters on heat treatment furnaces/ ovens can save up to 20% of fuel costs.

n Furnace oil Emusification Projects can save up to 10 % of Fuel.

n Fuel saving devices can save up to 10 % of fuel.

n Ceramic coating and replacement of inefficient burners can result in 10-20 % of savings in fuel consumption.

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ESCO COMPANY-

nOpel Energy Systems Pvt.Ltd., Pune.Office no. 12, Anantnagar, Pune- 4 3.Ph.Nos. 020 24377646, 09 921000930.

Email- ydc@vsnl.net, response@opelenerg ysystems.com

Websites- www.opelenerg ysystems.comwww.e nerg yconservation.co.in

Credentials for OESPL

n An ISO 9001-2008 Company.n Empanelled as ESCO with BEE.n Awarded first as ESCO by MEDA.n 15 Years of experience in energy field.nMore than 100 Encon project in v arious

industries are saving energy worth Rs. 600 lacs per year.

ENCON Projects form concept to commissioning with performance guarantee.

nWe conduct thermal energy Audit without any charges from Industry, who are really interested in doing energy conservation,this is to achieve our Motto, of saving energy for nation.

Solar Steam Generating Plant

WHRS on FurnaceHot Air Generator

1) Waste Heat Recovery Systems on Furnace.

n Equipment - Decarb Fu rnacen Exhaust Temp - 250 De g.Cn Out Put - Steam at 5 kg/cm2.n Quantity - 25 kgs/h r. n Savings in elect - 15 kwh/ hr.n Annual cost saving - Rs. 4.2 lac.n Pay back pe riod - 9 months.

2. Fuel saving devices on Burners.

n Proj ect- Fuel saving Devices on Boiler.n Thermal equipments- Steam Boilers.n Equipment ins talle d – Flu x maxio x fuel saving

devices- 3 nos. at Burne r inlet.n Output i ncreased – 4 % with clean combustion.n Cost s av ing per year - 12.8 lacs.n Inv estment for the fl ux dev ices- 1.35 lacsn Payback peri od- 1.5 Month.

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3) Waste Heat Recovery on D.G.set Exhaust at Auto ancillary unit.

n Equipment - 750 kva.D.G. Set2 nos.

n Stack Temp. - 450 Deg.CnOut Put - Hot Watern Heat recovered - 473000 Kcal/hrn Fuel Savings - 40 kg/hr LPGn Annual Saving - Rs. 20 lacs.n Pay back period - 10 months.

4) Waste Heat Recovery on D.G.setExhaust at Engg. Industry

n Equipment - Steam Boiler on2 nos.625 kv a.D.G. Sets

> Stack Temp. - 500 Deg.Cn Steam Out Put - 600 kg/hrn Heat recovered - 425000 Kcal/hrn Fuel Savings - 40 kg/hr HSDn Annual Saving - Rs. 42 lacs.n Pay back period - 6 months

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5) Waste Heat Recovery System on Annealing Furnace.

n Equipment - Annealing Furnacen Exhaust Temp. - 300 Deg.CnOut Put - Hot Water n Heat Recov ery - 100,000 kcal/hrn Cost of fuel saved- 18 lacs/year.n Pay back period- 9 months.

6 Waste Heat Recovery system on Oven Exhaust –TATA MOTORS.

FUEL SAVING THROUGH WASTE HEAT RECOVERYHeat recove ry unit installed at oven chimne y for heati ng the a quatherm water. This recovery uni t will mainta in the aquatherm water temp t ill the oven burner is runni ng. If add iti onal heat is required th en only aquathe rm wi ll get start automatically to mai ntai n the water temp . Earli er the water temperature was mai nt ained by switching aquatherm as per the water temperature feedb ack.

Ea rlier syst em After Modific ation Aft er Insu lation

WASTE HEAT REC OVE RY ON OVEN EX HAUST

n Equipment – Paint baking ovenn Fuel in use- LPG.n WHRS- Pressurized hot wate r gene rator.n Working tempe rature- 120 /14 0 deg. C.n Reduction in flue gas temp.- 250 to 150 deg.c.n LPG saving pe r hour- 2.4 kgs./ovenn Total Cost saved per ye ar- 22 lacs.n Project cost- 10 lacs.n Pay back pe riod- 6 mon ths.

7) F.O. Conversion System Core Drying Oven in foundry.

n Equipment - Core drying ovens.n Fuel in used -HSD.n System changed to - Furnace Oil.n Annual Cost saving - 100 lacs.n Project cost- 8.5 lacs.n Pay back period - 1 month Only.

F.O.Heating & pumping unit.

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8) Insulation to avoid surface losses

n Equipment-Core baking oven.n Fuel consumption -60 lits/hr.n Av erage surface temperature- 70 Deg.C.n Temp. after insulation- 40Deg.C.n Losses avoided – 345 kcal/sq.mtr/hr.n Total area insulated- 220 sq.mtr.n Cost saved in terms of F.O.- 11.32 lacs.n Pay back period- 6 months.

9) WaterEmulsification System for F.O.Conservation on Thermopacks.

n Equipment - Thermic Fluid Heaters. - 6lac kcal/hr. -4 nos.

n Fuel in use -F.O..n Encon project - Emulsificationn F.O.Saving achieved- 5 %. n Annual Cost saving – 13.5 lacsn Pay back period - 3 month Only.

10) Conversion of F.O.FIRED Equipment to Solid fuel f iring. ( Biomass Briquettes )

n Equipment- Pressuriz ed Hot water gener ator.

n Fuel firing rate- 1200 l its of Furnace Oi l.

n Equipment instal led – S olid fuel fired HWG.With operationa l contract inc luding supply of fuel.

n Cost of the fuel sav ed per day - Rs. 20000 / day.

n Project cost inc luding civi l cost- Rs. 30 lacs.

n Saving achived per year- Rs. 60 lacs.

n Simple pay back per iod- 6 months.

Solid Fuel Fired HWG Non Conventional Energy Generation Projects.n 1) Solar Steam Gener ation Plant for Industrial heating

app lication.

n 2) Industria l Cant een on non-convent ional Ener gy – where Solar steam is used for cooking & Biogas generated from waste food.

n Industria l Biogas Plants at-n 1) Cummins India Ltdn 2) Kirlosk ar pneum atic Co. Ltd.n 3) Kirlosk ar Ferrous Industries Ltd.n 4) Emerson Clim ate Technolog ies (Ind ia) Ltd.

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Solar Stea m Gene rating Pla nt.

n Tata motors ltd.n Emerson climate technologies( india) ltd.n Cummins india ltd.n Associated capsules Ltd.n Sundaramgroup of companies Ltd.n Varroc engineering Pvt Ltd.n Godrej & Boyes Ltd.n Tube investment of india Ltd.n Honeywell automations India Ltd. .n Scrubber Dynamix Dairies india Ltd.n Jayhind Industries Ltd.n Sterlite Industries Ltd.n Proctor & Gamble home products Ltd.n Kirloskar Ferrous Industries Ltd.n Amtek Industries Ltd.

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Import ance of ENCON in industry. REMEMBER

If you are wasting energy you are doing crime against Nation!

ANDIf you try to save energy you will be doing

prestigious work for Nation!

Call yourself URJA RAKSHAK for NATION!

For more details-

nOpel Energy Systems Pvt.Ltd., Pune.Office no. 12, Anantnagar, Pune- 4 3.Ph.Nos. 020 24377646, 09 921000930.

Email- ydc@vsnl.net, response@opelenerg ysystems.com

Websites- www.opelenerg ysystems.comwww.e nerg yconservation.co.in