WELCOME
DATE : 25/11/04
1
Who
Moved
My Oil ?
2
EMERGENCE OF PCRA
1973 : OIL CRISIS WORLD OVER
STUDY : ENGINEERS FROM IOC, NPC, DGTD
TEAM ESTIMATED HUGE OIL CONSERVATION
POTENTIAL IN INDUSTRIES & STUs
STUDY : CONSERVATION POTENTIAL
RESULTS OF 20 - 30%
6th JAN ’76 : PETROLEUM CONSERVATION ACTION
GROUP (PCAG) FORMED
10th : PCAG RECONSTITUTED AS
AUG’78 “PETROLEUM CONSERVATION
RESEARCH ASSOCIATION” (PCRA)
AND REGISTERED AS A SOCIETY
UNDER MOP&NG
3
SECTROAL APPROACH
COMMERCIAL
INDUSTRY AGRICULTURE
PCRA
TRANSPORT DOMESTIC
4
SCOPE OF ENERGY AUDIT
Sectoral Consumption of Energy (350 MMtoE)
100% Others (14%) 49 MMtoE
Domestic (10%) 35 MMtoE
80% Agriculture (5%) 17.5 MMtoE
DTP &MDP
Transport (22%) 77 MMtoE
60%
40%
Industry (49%) 171.5 Energy Audit
MMtoE
20%
0%
1
71% of the Energy Consumption comes under the ambit of PCRA
5
A GIST OF FIELD ACTIVITIES.
S. Activity Nos.
No. (Since 1985)
1. Energy Audits, Fuel Oil Studies, SSI, Follow ups 34910
2. Institutional training programme 1102
3. Model Depot Projects 1696
4. Driver Training Programme 4014
5. Rectification of LIPs & footvalves 30212
6. Demonstration Centre 411
7. Exhibitions, Seminars & Consumer Meets 945
8. Action Group Meetings 208
9. Youth Programme 6819
10. Van Publicity 3537
6
INCREMENTAL SAVINGS - ALL SECTORS
400
350 VALUE
([Link].)
275
300
250
220
200 QTY
(‘000 TONNES
150
100 QTY
50 VALUE
YEAR
7
RECURRING SAVINGS –
INDUSTRIAL SECTOR
1000 952.23
900 Qty
(‘000
800
Tonnes)
700
600 701.00
500 VALUE
400 ([Link])
300
200 QTY
100 VALUE
0
85-86 87-88 89-90 91-92 93-94 95-96 97-98 98-99 99-00 00-01 '01-02 '02-03 '03-
04(P)
YEAR
8
PHILOSOPHY OF ENERGY AUDIT
Through energy audit, we optimize the consumption of
fuel i.e. coal, electricity petroleum products etc.
To spread the benefits obtained through Energy Audit
in any one industry to entire cluster
To replicate the benefit obtained through Energy Audit
in other industries through Education Campaign and
ITPs
Sponsor R &D projects identified from Energy Audit.
9
Energy Audits in Clusters
(2001-02 to 2003-04)
Sl. Name of the Cluster No. of Annual Energy Saving
No. Industry Industries Consumption Potential
Audited (KLOE) Identified
(KLOE)
1 Aluminium 5 13570 936
2 Iron & Steel 62 133677 16276
3 Cement 2 37786 722
4 Pulp and paper 11 58297 3561
5 Sugar 1 1450 290
6 Textile 49 153770 6749
7 Chemical 30 56642 3366
8 Process Industries 131 290718 16882
9 Thermal Power Station 1 1800 257
10 Commercial Buildings 58 19199 1823
11 Hand Tools Industry 28 11020 1888
12 Milk Processing Industry 20 24311 1676
13 Food processing Industry 29 59771 4812
14 Petroleum 80 4930354 82643
15 Engineering 97 1172053 17326
16 Misc. 1 272 17
Total 604 6964417 159206
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MAJOR ENERGY AUDITS
(Since 2001)
Sl Name of Industry Type Audit City *EYC Savings % SI/
No Type** KLOE Identified EYC
(SI) KLOE
1. ONGC Natural Gas P Uran, Mumbai 128891 20834 16
2. IOC Blending Ltd. LO Blending P Vashi, 1750 205 12
Mumbai
3. IOC LPG Bottling LPG Bottling P Bhopal 1000 200 20
4. LPG Recovery LPG P Lakwa, 22470 2000 9
Plant, GAIL Recovery Assam
5. HPCL, Nagaon Paper Mill P Nagaon, 1600 190 12
Paper Mill Assam
6. Vishnu Chem (Units Chemical P Medak, A P 4120 900 22
I & II)
7. Mother Dairy Dairy P Delhi 1229 43 3
8. India Habitat Centre Office M Delhi 1338 96 7
9. Star Wire India Ltd Steel E Ballabhargh 1247 61 5
10. TELCO Automotive E Jamshedpur 10000 975 10
**P = Process; E=Engg; T=Textiles; G=Glass; M=Miscellaneous
*EYC indicates Estimate I Yearly Consumption of audited industrioes 11
MAJOR ENERGY AUDITS
(Since 2001)
Sl Name of Industry Type Audit City *EYC Savings % SI/
No Type** KLOE Identified EYC
(SI) KLOE
11. TVS Motor Co. Automotive E Hosur, 7920 715 11
Karnataka
12. Security Paper Mills Paper Mill P Hoshangabad, 11300 1840 16
MP
13. JK Pharma Chem Pharma- P Cuddalore, TN 8000 500 6
Ltd ceuticals
14. UPRVUNL Power E Anpara, UP 4776 232 5
15. Ginni Filaments Textile T Chhata, UP 13200 827 6
16. Hans Metals P Ltd. Metal E Kanpur, UP 2000 218 11
17. Hindalco Ind. Ltd Aluminium E Renukoot, UP 4476 498 11
18. Maxlux Glass P Ltd. Glass P Uluberia, WB 2448 345 14
19. Hindustan Iron & Steel E Kolkata 1400 123 9
Steel Co. Ltd.
20. Britania Industries Biscuit P Kolkata 1920 29 2
**P = Process; E=Engg; T=Textiles; G=Glass; M=Miscellaneous
*EYC indicates Estimate I Yearly Consumption of audited 12
Energy is Life
Conservation is instinct of life
GDP is inseparable from conservation /efficiency
Who are the Stake Holders?
13
ATMOSPHERE
ENVIRONMENT HYDROSPHERE
BIOSPHERE
FACTORY
PRODUCT MIX
MARKETS
LOGISTICS
CONSUMERS INDUSTRY
PROCESS ASSOCIATIONS
MACHINERY COMMERCE/BUSIN
SCALE ESS/TRADE
GOVERNMENTS
QUALITY IMPORTS /
POLICY EXPORTS
SAFETY
LAWS ECONOMY/
STAFF FINANCE/ BANKING
REGULATORS
COMMUNITY TAXES /
VENDORS INCENTIVES
INPUTS PROFITABILITY
14
Energy is :
Food, Fodder , Fiber, Fuel
Health
Safety
Climate
Any greater cause than energy
conservation?
15
Who
Moved
My Water?
16
Energy is Consumed for emotional uplift like
consumerism, competition, convenience, comfort,
life style, luxury etc.
Energy & energy conservation is an issue of
1. Attitude
2. Values
3. Beliefs
4. Practices
17
Energy is an Emotion more than Knowledge
• The T&D losses in Mumbai, Calcutta & Delhi
are 10-11%, 18-19% & 30% respectively. In
certain states it is 50%
• Russia took 12 years to ratify Kyoto Protocol
• USA is not convinced yet to ratify Kyoto
Protocol
18
Energy & Resources
50 years back we knew Drinking Water was
free. Today it is NOT
Drinking water extraction in future may use oil
drilling like technology and vast process plants to
make the water potable.
Where is the energy for this future?
19
Energy & Resources
All of us believe today that Air is Free. Will
it follow the route of Drinking Water in
future?
For combustion and release of energy, air is
as important as fuel if not more. How many
of us measure and control the combustion
process in totality ?.
20
Energy & Resources
How many of us check the air filter vis-à-
vis the fuel tank level of our automobiles ?
Can you risk to Guess , billions of US
dollars of packaged air in future and the
life forms?
forms
21
Who
Moved
My Air?
22
PCRA’s Mixed Experience
Enlightened industry is employing OEMs &
Technology suppliers to do Energy Audit at regular
intervals
MNCs are conducting Energy Audits of their
vendor’s units over decades
Tea, Salt & Chemical Industry using water
circulators or thermic fluid heaters to preheat air as a
via media
23
PCRA’s Mixed Experience
Hotels are generating hot water from DG set hot
flue gas. Hotels are using boilers to generate steam
and run vapour absorption refrigeration systems
A very enlightened salt industry using vacuum
flash for drying salt. Producing pure water &
conserving ground water. A two in one salt
manufacture cum desalination! Or is it Three in
One?
24
PCRA’s Mixed Experience
Some industries still are ignorant and
secretive. Unwilling to allow the energy
auditors to see the process, plant, quality
control deptt etc. They still believe energy
conservation is on boiler floor and motor
drives only
25
PCRA’s Mixed Experience
The garbage collector’s van getting filled fastest.
Sometimes some houses remain uncollected. The
garbage collector wades through the traffic in
search of easy / quick dumping grounds. Now the
house holder is waiting in advance for the
garbage collector to deposit / dispose off his
consumption.
An increasing tendency of the industry to consume
wood in boilers/ furnaces in place of oil/ coal
26
Who
Moved
My Coal ?
27
PCRA’s Experience
PCRA does the scoping study, meeting &
discussing with people, process study, equipment
wise study, literature study etc before detailed
energy audit. In a way we establish full
communication by knowing the language of the
industry.
In a textile spinning mill the exhaust fans were of
overcapacity compared to inlet fans
28
PCRA’s Experience
Selection of suitable number of inlet fans,
water spray pumps, exhaust fans along with
relative humidity measurement saved 2.5
lacs KWh/Annum
29
PCRA’s Experience
Air compressor appears to follow 80:20
principle. It delivers only 20% effective output
and wastes 80% of the input. Due to
- Deteriorated performance of internals
- Compressed air leaks
- Air pressure selection
- Single stage operation
30
PCRA’s Experience
- Inter stage coolers
- cooling Water Treatment
- Cooling Tower Performance
- Pressure drop
31
PCRA’s Experience
- In a dry cell manufacturing plant one of
the four compressors could be stopped
- 5% of the electricity generated in the country
runs air compressors
In a foundry the used sand of moulds is recycled
after removal of organic binders and flux. The dryer
used for this purpose was kept over fired to be on the
safe side. An appreciation of quality measurement of
fresh and recycled sands reduced the fuel
consumption.
25.11.04
32
PCRA’s Experience
A steam less dairy that uses only hot water
circulation. No boiler, no [Link] dairy
does not have milk powder in the product
mix
25.11.04
33
PCRA’s Experience
Optimizing refrigeration loads in a dairy.
20% of refrigeration loads were reduced by
- off peak operation of refrigeration for
ice build up in IBT
- Sequencing of IBT operation & avoid
unnecessary ice build up with respect
to stocks & expected inputs
34
PCRA’s Experience
- Control of ice build up to maximum 2 inch
- Automatic instrumentation for heating
and chilling to avoid over heating / fouling
& over chilling/ too low suction pressure.
- optimum insitu cleaning to improve
regeneration efficiency. Save
water/chemicals too
35
PCRA’s Experience
- Monitoring and adjusting cooling tower
for the rated range and approach. This
alone controls the Discharge Pressure of
the compressor
- Calculate regeneration efficiency in every
shift. Aim for 90%
36
PCRA’s Experience
In a Mirinda Orange Drink Plant found that it’s CO2
absorption requirement was half compared to exotic Coco-
Cola. Higher temperature of chilling for the desi drinks are
enough. Different energy settings for different product mix.
In a latex plant the OEM has set the chiller at +6 0 C of
product temperature. The process needed higher
temperature of 16 0 C! In operation, the product was shock
chilled and allowed to thaw!! A good example of energy
conservation at the interface of the equipment and process.
The machine needs reset for a product outlet temp of 16 0 C.
37
PCRA’s Experience
An FMCG major was connected from an
agricultural feeder. The voltage fluctuation
causing recurrent disruptions. They were
running DG sets at 20% load factor and
disconnected the EB feeder. Suggested lock
rotor protection/ re-acceleration after carrying
equipment wise no load / part load/ full load
readings. The EB feeder was revived. DG set
shutdown.
38
PCRA’s Experience
In an asbestos plant, the asbestos, cement and fly
ash slurry is processed in a vacuum drum filter for
required thickness of sheets. The vacuum pump
discharge temperature is 80 0 C. Suggested to
utilize this waste heat to dry the sheets and reduce
fuel firing and electricity
Amazing, is it not?
Lot of low lying fruits!
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OPPORTUNINITES GALORE
TOP 10 PRIVATE COS ACCORDING TO POWER & FUEL COST(Rs. Crores)
COMPANY POWER & FUEL % P&F/Tot Exp (%)
03-04 02-03 Ch 03-04 02-03
ESSAR STEEL 1108 873 26.9 38.8 38.3
GRASIM IND 889 856 3.9 22.6 23.7
ACC 744 706 5.4 25.6 27.5
RELIANCE IND 725 719 0.8 1.8 2.3
TISCO 668 788 -15.3 9.0 11.8
CHAMBAL FERT 554 481 15.2 30.5 31.7
CENTURY TEXTILES 495 466 6.3 25.5 25.3
GUJ AMBUJA CEM 431 324 32.9 34.2 34.5
BALLARPUR IND 412 384 7.3 26.5 34.0
INDIAN ALUMINIUM 378 347 9.0 27.8 29.3
TOTAL(201) 14780 13694 7.9 8.9 9.6
25.11.04 [Link] Express, Chennai 22.06.04 40
Who
Moved
My Electricity?
41
Concepts for Future
Individual Carbon Neutrality
Distributed Production for Distributed
Consumption
Asymptote Nature?
Ecological
Degradation But ………
Production Engages
People + Locations
42
Concepts for Future
Food Miles
Up-gradation / harvesting of low grade energy
sources (sun light, low [Link] of flue gas
from boiler, furnace, engines, low velocity wind
by thermo compressors, heat pumps etc)
Awakening on common property rights of air,
water, earth, sky….
43
Concepts for Future
Conflict resolution between interest holders of
food, fibre, fodder, fuel
NPT on automobiles
Nuclear power for H2 production / desalination
Recycling industries for ferrous/ non-ferrous
metals, plastics, paper etc.
44
Concepts for Future
Consumers shall pay for the cost of pollution
(producer shall pay …..is past)
Press the Best Individuals, Institutions,
Organizations, & Resources for energy
conservation. e.g Brand Ambassadors of the
FMCG, Media, Chartered Accountants etc. This
will ensure sustainable business as well as life
45
Concepts for Future
ICAI published a book on energy audit and
management.
46
Concepts for Future
Enjoy the interest on the principal of
nature’s bounty. Do not treat it as booty.
Mankind should not be the worst NPA
amongst the life forms.
47
Save Energy
Save Yourself
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LINK 49
