Energy Auditing

Rangan Banerjee Energy Systems Engineering IIT Bombay

Talk delivered at MITCON Course April 1,2005

Need for Energy Management

Renewables In general , not yet costeffective Capital Scarcity- Payment Crisis of Subsidised Energy Sectors Gestation Period for New Power plants Least Cost Planning Energy Management Transition fuel

Importance of Energy Conservation

Energy Conservation Act 2001 Setting up of the Bureau of Energy Efficiency (March 2002) Standards and Labelling Energy Conservation Fund Designated ConsumersEnergy audits by accredited auditors Certified energy managers Norms and standards of energy consumption

Energy Cost in Chemical Industry

12% of manufacturing cost. Real growth in energy bill higher than real growth in raw material, sales. Higher energy prices competitive disadvantage (compared to US, UK, Brazil, France) Electricity accounts for 44% of fuel mix. Electricity price increasing at higher rates than other fuels (10% per year real growth).

EC Company Policy
Many companies declared EC policy , in response to a request by Energy Management Centre for example

Reliance : Our mission is

to be the lowest specific energy consumer in the industry we operate in To maximise the use of renewable fuels and low energy level fuels in our operations Mukesh Ambani

Energy Conservation Opportunities

Design Stage
Efficient process design Efficient equipment design/ selection Efficient Utility System design

Operating DecisionsEnergy Auditing Operating Strategies Retrofit equipment Replace equipment/processes

What is an energy audit?

Audit financial connotation examination with an intent to verify Energy audit coined in the 70s after the oil shocks

An energy audit is a study of a plant or facility to determine how and where energy is used and identify methods for energy savings

DEFINE AUDIT OBJECTIVES

QUESTIONNAIRE

REVIEW PAST RECORDS

WALK THROUGH / PLANT FAMILIARISATION

DATA REQUIREMENTS DATA ANALYSIS MEASUREMENTS / TESTS

COMPUTE MASS / ENERGY BALANCES INSTALL MEASURES ENUMERATE ENERGY CONSERVATION OPPORTUNITIES

EVALUATE ECOs

PRIORITISE RECOMMENDATIONS

P a ra m e te r T e m p e ra tu re

S u b -T y p e C o n ta c t ty p e

N o n -c o n ta c t ty p e F lo w

N o n - in v a s i v e F lu e a n a ly s is gas

Power RPM T o t a l d is s o lv e d s o li d s L i g h t in g C o n ta c t N o n -c o n ta c t

In s tru m e n ts T h e r m o c o u p le s e . g . ( K t y p e C h r o m e l- A lu m e l ) -2 0 0 to 1 3 0 0 C R e s is ta n c e T e m p e ra tu re D e te c to rs (R T D s ) 0 to 1 5 0 C S u c t io n P y r o m e t e r R a d ia t io n P y r o m e t e r s T w o c o lo u r o p t ic a l p y r o m e t e r s F ix e d a r e a ( O r if ic e , V e n t u r i ) V a r ia b le a r e a ( R o t a m e t e r ) P it o t s t a t ic t u b e H o t w ir e a n e m o m e t e r U lt r a - s o n ic f lo w m e t e r D o p p le r m e t e r s Z ir c o n iu m o x id e o xyg e n s e n s o rs P a r a m a g n e t ic a n a ly s is fo r o xyg e n F u e l c e lls f o r C O 3 - P h a s e c la m p o n m u lt im e t e r (3 w a tt m e te r m e th o d ) T a c h o m e te r

C o n d u c t iv it y m e t e r s L u x m e te r

Suction Pyrometer
Thermocouple junction Aluminum Shield

Radiation Shield 27 mm

43 mm Operating Length

Suction Line Water outlet Water inlet

Gases

Data Sources
Electrical line Diagram P & I Diagram Steam Distribution Diagram Nameplate Ratings Manufacturers Catalogs (Major eqpt) Logsheet data (Typical days)

11 kV CPP1

11 kV CPP 2

11/6.6 kV Trf-1 6.6 kV CB

11/6.6 kV Trf-2 6.6 kV CB

MCC-1 6.6/0.44 kV Trf-3

BUS COUPLER

MCC-2

HT Motor loads

HT Motor loads

LT Loads

Schematic of Electric Supply network

Sankey Diagram
Mass and Energy Balances for a process Relative magnitudes- quantification of energy flows Design Balance /Operating Balance

Block Diagram for a Cement Plant

Sankey Diagram for a Cement Plant

Energy Efficiency
Determine end-use profile of plant load Motors (80% of load), lighting, heating Breakup of motor load for a Chemical plant
Conveyors (5.5 %) Centrifuges (1.3 %) Agitators (12.7 %) Others (15.9 %)

Pumps (51.3 %)

Compressors (1.3 %)

Fans (11.9 %)

Energy Conservation Opportunities

Housekeeping/Monitoring Additional Equipment Equipment Replacement/Efficient Equip. Operating Strategies Process Integration/Networking Process Changes

Typical Audit Summary

OPTION ENERGY
WASTE HEAT RECOVERY (FLUE GASES) 3.4 MW 19.3 Mus - 105,500Nm3 2.7 MW 16.2 MUS 97,000 kWh 2.9 CR I : 8.9 CR 2.4 CR I : 6 CR 1.45 LAKHS I : 1.26 LAKHS 26 LAKHS 0.17 LAKHS I : 0.53 LAKHS 17 LAKHS

ANNUAL SAVINGS MONEY(Rs.)

VIABILITY

SPP 3.1 YR IRR 40 % NPV 15.8 CR SPP 2.5 YR IRR 40 % NPV 14.7 CR SPP < 1 YR

TOP GAS HEAT RECOVERY

AUTO Y-- Y SPEED CONTROL F.D. FAN FRP BLADES COLLING TOWER COOLING WATER OPERATIONS

1,704,000 kWh 11,100 kWh 1,125,000 kWh

SPP 3.2 YRS -

Practical Difficulties
Data Insufficiency Data Inconsistency Incomplete Evaluation of Options Changes in External Environment

IRON OXIDE + PELLETS S H A F T F U R N A C E 140MW

Top Gas 360oC S C R U B B E R

REFORMED GAS
940oC

FLUE GAS
1100oC

RECUPERATOR REFORMER 62 MW 38 MW
AIR
40oC

570oC

NG
FUEL HBI BRIQUETTING M/C 80oC FEED GAS FLUE GAS To Chimney 50oC 630oC

286oC

Schematic of HBI Plant

EXHAUST

AIR

TILES AIR BURNER AIR

OIL

OIL

Schematic of Glost Kiln in Tile Factory

RAPID COOLING

COOLING EXHAUST

BLAST

1000kVA DG1

Exhaust gases 12oC

400TR QR 7oC
VARS

1000kVA DG2
1.8 T/hr

8ATA DG3 1000kVA

WASTE HEAT BOILER1 WASTE HEAT BOILER2

400 kg/hr IT/hr BOILER 1

400 kg/hr BOILER 2

Total Load Curve of IIT

Working da y

Average power factor of the day

Non working da y

3000 2500 2000 1500 1000 500 0

Working day-0.96 Non-working day-0.97

2 5 10 k VA

19 0 0 k VA

1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16 17 18 1920 21222324 Time h o u rs

MAXIMUM DEMAND
Variation of Maximum Demand For year 2000-01 4000
Maximum Demand (kVA)
3080

Contract demand 3000 kVA 75 % CD 2250 kVA

3000 2000 1000 0

2900

2840

2780

2960

2880

3120

2928 2500

3040 2800 2640

Penalty paid by IIT

0 M ay '0 0 Ju n' 00 Ju l' 0 0 Au g' 00 Se p' 00 O ct '0 0 N ov '0 0 D ec '0 0 Ju n' 01 Fe b' 01 M ar '0 1

r' 0

Ap

For year 2000-1 Rs.38400

Month

Power Factor Correction

P- Active Power (kW)
SAp pa re

nt P

Q- Reactive
ow er

Power
(k VA

(kVAr)
)

POWER FACTOR IMPROVEMENT

AUTOMATIC POWER FACTOR CORRECTION 0.95 to 0.99 Reduction in MD- 107 kVA/month Annual Saving -Rs.3.85 lakhs Cost of the APFC unit Rs. 2.5 lakhs (with 150 kVAr capacitor units) Simple Payback Period - 8 months

Departmental Connected Load by End-use

Pumping Load 7% Others 3% Lighting 16% Laboratory 31% Air Conditioning 32%

Fan 4% Computer 7%

Total 4300 kW connected load

ENERGY EFFICIENT LIGHTING

Group Control Master Switch outside classrooms Common Area Lighting Photocells for group switching Tubelights Electronic Ballasts for high duty cycle tubes Efficient tubelights (26 W)

Duty Cycle of Tubelights

Number of Tubelights vs Hours of Operation

44 6
Hours of Operation

340 354 706 1196 414 577 759 85 87 277

0 200 400 600 800 1000 1200 1400

8 10 12 14 16 18 18+

Number of Tubelights

Harmonic Restraint Electronic Ballasts

THD <5 %

Conventional

FTL Options
Electronic Ballast Consumption 2-3 W instead of 12-15 W as replacements when failure ,Incremental Rs 700, Duty cycle (14 hours or more), Rs 200/yr saving Efficient slim tube 26 W (10 W saving), Investment Rs 780 Try out a few for high duty cycle

Duty Cycle of Fans

Electronic Regulators for high duty cycle on replacement

44 6 8 10 12 14 16 18 18+

Hours of Operation

59 135 287 543 54 8 14 69 100 200 300 Num ber of Fans 400 500 600 111 135

METERING
Digital meters at 25 locations (Depts/pumping stns/Main Building) with meter reader (Rs. 1.5 lakhs for meters) or Automatic metering and Energy balancing through networking at 25 locations (Rs. 10 lakhs app.) Billing to Departments Norm Establishment (after initial data collection)

References
Witte, Schmidt, Brown, Industrial Energy Management and Utilisation, Hemisphere Publ,Washington,1988 S.Khurana, R.Banerjee, U.N.Gaitonde, Applied Thermal Engineering,Vol22, p485-494,2002 E. Worrell,Potential for Improved Industrial Energy Use and Materials,Ultrecht,1994