WELCOME

DATE : 25/11/04
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Who Moved My Oil ?

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EMERGENCE OF PCRA
 1973  STUDY TEAM  STUDY RESULTS : OIL CRISIS WORLD OVER : ENGINEERS FROM IOC, NPC, DGTD ESTIMATED HUGE OIL CONSERVATION POTENTIAL IN INDUSTRIES & STUs : CONSERVATION POTENTIAL OF 20 - 30%

 6th JAN 76 : PETROLEUM CONSERVATION ACTION GROUP (PCAG) FORMED  10th AUG78 : PCAG RECONSTITUTED AS PETROLEUM CONSERVATION RESEARCH ASSOCIATION (PCRA) AND REGISTERED AS A SOCIETY UNDER MOP&NG
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SECTROAL APPROACH

COMMERCIAL INDUSTRY AGRICULTURE

PCRA

TRANSPORT

DOMESTIC

SCOPE OF ENERGY AUDIT

Sectoral Consumption of Energy (350 MMtoE)
100%

Others (14%) 49 MMtoE

Dome stic (10%) 35 MM toE

80%

Agriculture (5%) 17.5 MMtoE Transport (22%) 77 MMtoE

DTP &MDP

60%

40% Industry (49%) 171.5 MMtoE 20%

Energy Audit

0%
71% of the Energy Consumption comes under the ambit of PCRA

A GIST OF FIELD ACTIVITIES.

S. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. Activity Energy Audits, Fuel Oil Studies, SSI, Follow ups Institutional training programme Model Depot Projects Driver Training Programme Rectification of LIPs & footvalves Demonstration Centre Exhibitions, Seminars & Consumer Meets Action Group Meetings Youth Programme Nos. (Since 1985) 34910 1102 1696 4014 30212 411 945 208 6819 3537
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10. Van Publicity

100

150

200

250

400

300

350

50

0
85 -8 6 86 -8 7 87 -8 8 88 -8 9 89 -9 0 90 -9 1 91 -9 2 92 -9 3 93 -9 4 94 -9 5 95 -9 6 96 -9 7 97 -9 8 98 -9 9 99 -0 0 00 -0 1 0 1 -0 2 0 2 -0 3 0 3 -0 4 (P)

INCREMENTAL SAVINGS - ALL SECTORS

YEAR
QTY VALUE

275

220

VALUE (Rs.Crs.)

QTY (000 TONNES)

RECURRING SAVINGS INDUSTRIAL SECTOR

1000 900 800 700 600 500 400 300 200 100 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 '0304(P)

952.23 Qty (000 Tonnes) 701.00 VALUE (Rs.Crs)

QTY VALUE

YEAR

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.

Energy Audits in Clusters (2001-02 to 2003-04)

Sl. Name of the Cluster No. Industry No. of Industries Audited 5 62 2 11 1 49 30 131 1 58 28 20 29 80 97 1 604 Annual Energy Consumption (KLOE) 13570 133677 37786 58297 1450 153770 56642 290718 1800 19199 11020 24311 59771 4930354 1172053 272 6964417 Saving Potential Identified (KLOE) 936 16276 722 3561 290 6749 3366 16882 257 1823 1888 1676 4812 82643 17326 17 159206

1 2 3 4 5 6 7 8 9

Aluminium Iron & Steel Cement Pulp and paper Sugar Textile Chemical Process Industries Thermal Power Station

10 Commercial Buildings 11 Hand Tools Industry 12 Milk Processing Industry 13 Food processing Industry 14 Petroleum 15 Engineering 16 Misc. Total

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MAJOR ENERGY AUDITS

(Since 2001)
Sl No 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Name of Industry Type Audit Type** P P P P P P P M E City *EYC KLOE 128891 1750 1000 22470 1600 4120 1229 1338 1247 Savings Identified (SI) KLOE 20834 205 200 2000 190 900 43 96 61 975 % SI/ EYC 16 12 20 9 12 22 3 7 5 10

ONGC IOC Blending Ltd. IOC LPG Bottling LPG Recovery Plant, GAIL HPCL, Nagaon Paper Mill Vishnu Chem (Units I & II) Mother Dairy India Habitat Centre Star Wire India Ltd

Natural Gas LO Blending LPG Bottling LPG Recovery Paper Mill Chemical Dairy Office Steel

Uran, Mumbai Vashi, Mumbai Bhopal Lakwa, Assam Nagaon, Assam Medak, A P Delhi Delhi Ballabhargh

TELCO Automotive E Jamshedpur 10000 **P = Process; E=Engg; T=Textiles; G=Glass; M=Miscellaneous *EYC indicates Estimate I Yearly Consumption of audited industrioes

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MAJOR ENERGY AUDITS

(Since 2001)
Sl No 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Name of Industry Type Audit Type** E P P E T E E P E P City *EYC KLOE 7920 11300 8000 4776 13200 2000 4476 2448 1400 1920 Savings Identified (SI) KLOE 715 1840 500 232 827 218 498 345 123 29 % SI/ EYC 11 16 6 5 6 11 11 14 9 2

TVS Motor Co. Security Paper Mills JK Pharma Chem Ltd UPRVUNL Ginni Filaments Hans Metals P Ltd. Hindalco Ind. Ltd Maxlux Glass P Ltd. Hindustan Iron & Steel Co. Ltd. Britania Industries

Automotive Paper Mill Pharmaceuticals Power Textile Metal Aluminium Glass Steel Biscuit

Hosur, Karnataka Hoshangabad, MP Cuddalore, TN Anpara, UP Chhata, UP Kanpur, UP Renukoot, UP Uluberia, WB Kolkata Kolkata

**P = Process; E=Engg; T=Textiles; G=Glass; M=Miscellaneous *EYC indicates Estimate I Yearly Consumption of audited industrioes

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Energy is Life Conservation is instinct of life GDP is inseparable from conservation /efficiency Who are the Stake Holders?

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ATMOSPHERE ENVIRONMENT HYDROSPHERE BIOSPHERE FACTORY PRODUCT MIX LOGISTICS PROCESS MACHINERY SCALE QUALITY SAFETY STAFF COMMUNITY VENDORS INPUTS GOVERNMENTS POLICY LAWS REGULATORS MARKETS CONSUMERS INDUSTRY ASSOCIATIONS COMMERCE/BUSIN ESS/TRADE IMPORTS / EXPORTS ECONOMY/ FINANCE/ BANKING TAXES / INCENTIVES PROFITABILITY 14

Energy is :  Food, Fodder , Fiber, Fuel  Health  Safety  Climate

 Any greater cause than energy conservation?
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Who Moved My Water?

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 Energy is Consumed for emotional uplift like consumerism, competition, convenience, comfort, life style, luxury etc.  Energy & energy conservation is an issue of 1. 2. 3. 4. Attitude Values Beliefs Practices
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 Energy is an Emotion more than Knowledge The T&D losses in Mumbai, Calcutta & Delhi are 10-11%, 18-19% & 30% respectively. In 1018certain states it is 50% Russia took 12 years to ratify Kyoto Protocol USA is not convinced yet to ratify Kyoto Protocol
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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?

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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 ?.
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Energy & Resources

How many of us check the air filter vis-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

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Who Moved My Air?

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PCRAs Mixed Experience

 Enlightened industry is employing OEMs & Technology suppliers to do Energy Audit at regular intervals  MNCs are conducting Energy Audits of their vendors units over decades  Tea, Salt & Chemical Industry using water circulators or thermic fluid heaters to preheat air as a via media
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PCRAs 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?
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PCRAs 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

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PCRAs Mixed Experience

 The garbage collectors 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

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Who Moved My Coal ?

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PCRAs 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

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PCRAs Experience
Selection of suitable number of inlet fans, water spray pumps, exhaust fans along with relative humidity measurement saved 2.5 lacs KWh/Annum

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PCRAs 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

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PCRAs Experience

 - Inter stage coolers - cooling Water Treatment - Cooling Tower Performance - Pressure drop

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PCRAs 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 flux. dryer used for this purpose was kept over fired to be on the safe side. An appreciation of quality side. measurement of fresh and recycled sands reduced the fuel consumption. consumption.
25.11.04

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PCRAs Experience
 A steam less dairy that uses only hot water circulation. No boiler, no steam.This dairy does not have milk powder in the product mix

25.11.04

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PCRAs 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
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PCRAs 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
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PCRAs Experience
- Monitoring and adjusting cooling tower for the rated range and approach. This approach. alone controls the Discharge Pressure of the compressor - Calculate regeneration efficiency in every shift. Aim for 90%

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PCRAs Experience
 In a Mirinda Orange Drink Plant found that its CO2 absorption requirement was half compared to exotic Coco-Cola. Coco-Cola. Higher temperature of chilling for the desi drinks are enough. Different energy settings for enough. different product mix. mix.  In a latex plant the OEM has set the chiller at +6 0 C of product temperature. The process needed higher temperature. 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 process. outlet temp of 16 0 C.
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PCRAs Experience
 An FMCG major was connected from an agricultural feeder. The voltage fluctuation feeder. causing recurrent disruptions. They were disruptions. running DG sets at 20% load factor and 20% disconnected the EB feeder. Suggested lock feeder. rotor protection/ re-acceleration after carrying reequipment wise no load / part load/ full load readings. readings. The EB feeder was revived. DG set revived. shutdown. shutdown.
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PCRAs 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 ESSAR STEEL GRASIM IND ACC RELIANCE IND TISCO CHAMBAL FERT CENTURY TEXTILES GUJ AMBUJA CEM BALLARPUR IND

POWER & FUEL 03-04 02-03 1108 889 744 725 668 554 495 431 412 873 856 706 719 788 481 466 324 384

% Ch 26.9 3.9 5.4 0.8 -15.3 15.2 6.3 32.9 7.3

P&F/Tot Exp (%) 03-04 02-03 38.8 22.6 25.6 1.8 9.0 30.5 25.5 34.2 26.5 38.3 23.7 27.5 2.3 11.8 31.7 25.3 34.5 34.0

INDIAN ALUMINIUM TOTAL(201)

25.11.04

378 14780

347 13694

9.0 7.9

27.8 8.9

29.3 9.6 40

Ref.Financial Express, Chennai 22.06.04

Who Moved My Electricity?

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Concepts for Future

 Individual Carbon Neutrality  Distributed Production for Distributed Consumption
Asymptote Nature?
Ecological Degradation Production Engages People + Locations 42

But

Concepts for Future

 Food Miles  Up-gradation / harvesting of low grade energy Upsources (sun light, low temp.heat 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.
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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 nonmetals, plastics, paper etc.

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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 etc. will ensure sustainable business as well as life
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Concepts for Future

ICAI published a book on energy audit and management.

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Concepts for Future

Enjoy the interest on the principal of natures bounty. Do not treat it as booty. bounty. booty. Mankind should not be the worst NPA amongst the life forms. forms.

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Save Energy Save Yourself

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LINK

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