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WELCOMEDATE : 25/11/04

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Who Moved

My Oil ?

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EMERGENCE OF PCRA

1973 : OIL CRISIS WORLD OVER

STUDY TEAM

: ENGINEERS FROM IOC, NPC, DGTD ESTIMATED HUGE OIL CONSERVATION POTENTIAL IN INDUSTRIES & STUs

STUDY RESULTS

: CONSERVATION POTENTIAL OF 20 - 30%

6th JAN ’76 : PETROLEUM CONSERVATION ACTION GROUP (PCAG) FORMED

10th AUG’78

: PCAG RECONSTITUTED AS“PETROLEUM CONSERVATION RESEARCH ASSOCIATION” (PCRA) AND REGISTERED AS A SOCIETY UNDER MOP&NG

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SECTROAL APPROACH

PCRA

INDUSTRY AGRICULTURE

TRANSPORT DOMESTIC

COMMERCIAL

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SCOPE OF ENERGY AUDIT

Industry (49%) 171.5 MMtoE

Transport (22%) 77 MMtoE

Agriculture (5%) 17.5 MMtoE

Domestic (10%) 35 MMtoE

Others (14%) 49 MMtoE

0%

20%

40%

60%

80%

100%

1

Sectoral Consumption of Energy (350 MMtoE)

DTP &MDP

Energy Audit

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

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S. No.

Activity Nos.

(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

A GIST OF FIELD ACTIVITIES.

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0

50

100

150

200

250

300

350

400

QTY

VALUE

YEAR

VALUE(Rs.Crs.)

QTY(‘000 TONNES)

220

275

INCREMENTAL SAVINGS - ALL SECTORS

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0

100

200

300

400

500

600

700

800

900

1000

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)

QTYVALUE

YEAR

VALUE(Rs.Crs)

Qty(‘000

Tonnes)

952.23

701.00

RECURRING SAVINGS –INDUSTRIAL SECTOR

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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.

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

Sl.No.

Name of the ClusterIndustry

No. of Industries Audited

Annual Energy Consumption(KLOE)

Saving Potential 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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Sl No

Name of Industry Type Audit Type**

City *EYC KLOE

Savings Identified (SI) KLOE

% SI/ EYC

1. ONGC Natural Gas P Uran, Mumbai 128891 20834 16

2. IOC Blending Ltd. LO Blending P Vashi, Mumbai

1750 205 12

3. IOC LPG Bottling LPG Bottling P Bhopal 1000 200 20

4. LPG Recovery Plant, GAIL

LPG Recovery

P Lakwa, Assam

22470 2000 9

5. HPCL, Nagaon Paper Mill

Paper Mill P Nagaon, Assam

1600 190 12

6. Vishnu Chem (Units I & II)

Chemical P Medak, A P 4120 900 22

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

MAJOR ENERGY AUDITS (Since 2001)

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Sl No

Name of Industry Type Audit Type**

City *EYC KLOE

Savings Identified (SI) KLOE

% SI/ EYC

11. TVS Motor Co. Automotive E Hosur, Karnataka

7920 715 11

12. Security Paper Mills Paper Mill P Hoshangabad, MP

11300 1840 16

13. JK Pharma Chem Ltd

Pharma-ceuticals

P Cuddalore, TN 8000 500 6

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 Co. Ltd.

Steel E Kolkata 1400 123 9

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 industrioes

MAJOR ENERGY AUDITS (Since 2001)

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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

CONSUMERS

GOVERNMENTS

POLICY

LAWS

REGULATORS

MARKETS

INDUSTRY ASSOCIATIONS

COMMERCE/BUSINESS/TRADE

IMPORTS / EXPORTS

ECONOMY/ FINANCE/ BANKING

TAXES / INCENTIVES

PROFITABILITY

FACTORY

PRODUCT MIX

LOGISTICS

PROCESS

MACHINERY

SCALE

QUALITY

SAFETY

STAFF

COMMUNITY

VENDORS

INPUTS

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Energy is : Energy is :

Food, Fodder , Fiber, FuelFood, Fodder , Fiber, Fuel

HealthHealth

SafetySafety

ClimateClimate

Any greater cause than energy Any greater cause than energy

conservation?conservation?

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WhoMoved

My Water?

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Energy is Consumed for Energy is Consumed for emotional upliftemotional uplift like like consumerism, competition, convenience, consumerism, competition, convenience, comfort, life style, luxury etc.comfort, life style, luxury etc.

Energy & energy conservation is an issue of Energy & energy conservation is an issue of

1.1. AttitudeAttitude2.2. ValuesValues3.3. BeliefsBeliefs4.4. PracticesPractices

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Energy is an Emotion more than KnowledgeEnergy is an Emotion more than Knowledge

• The T&D losses in Mumbai, Calcutta & Delhi The T&D losses in Mumbai, Calcutta & Delhi are 10-11%, 18-19% & 30% respectively. In are 10-11%, 18-19% & 30% respectively. In certain states it is 50%certain states it is 50%

• Russia took 12 years to ratify Kyoto ProtocolRussia took 12 years to ratify Kyoto Protocol

• USA is not convinced yet to ratify Kyoto USA is not convinced yet to ratify Kyoto ProtocolProtocol

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50 years back we knew Drinking Water was 50 years back we knew Drinking Water was free. Today it is NOTfree. 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?Where is the energy for this future?

Energy & Resources

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All of us believe today that Air is Free. Air is Free. Will Will it follow the route of Drinking Water in it follow the route of Drinking Water in future?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 ?.

Energy & Resources

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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 airpackaged air in future and the life formslife forms?

Energy & Resources

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Who Moved My Air?

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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

PCRA’s Mixed Experience

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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?

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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 believeThey still believe energy energy conservation is on boiler floor and motor conservation is on boiler floor and motor drives onlydrives only

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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 Now the house holder is waiting in advance for the house holder is waiting in advance for the garbage collector to deposit / dispose off his garbage collector to deposit / dispose off his consumption.consumption.

An increasing tendency of the industry to consume wood in boilers/ furnaces in place of oil/ coal

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WhoMoved

My Coal ?

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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 language of the industry.industry.

In a textile spinning mill the exhaust fans were of overcapacity compared to inlet fans

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

PCRA’s Experience

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Air compressor appears to follow 80:20 Air compressor appears to follow 80:20 principle. It delivers only 20% effective output principle. It delivers only 20% effective output and wastes 80% of the input. Due toand wastes 80% of the input. Due to

- Deteriorated performance of internals- Deteriorated performance of internals - Compressed air leaks- Compressed air leaks - Air pressure selection- Air pressure selection - Single stage operation- Single stage operation

PCRA’s Experience

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- Inter stage coolers- Inter stage coolers

- cooling Water Treatment- cooling Water Treatment

- Cooling Tower Performance- Cooling Tower Performance

- Pressure drop - Pressure drop

PCRA’s Experience

25.11.04 32

- - In a dry cell manufacturing plant one of In a dry cell manufacturing plant one of the four compressors could be stoppedthe four compressors could be stopped - - 5% of the electricity generated in the country 5% of the electricity generated in the country runs air compressorsruns air compressors In a foundry the used sand of moulds is recycled In a foundry the used sand of moulds is recycled

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

PCRA’s Experience

25.11.04 33

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

PCRA’s Experience

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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

PCRA’s Experience

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- Control of ice build up to maximum 2 inch- Control of ice build up to maximum 2 inch

- Automatic instrumentation for heating - Automatic instrumentation for heating and chilling to avoid over heating / fouling and chilling to avoid over heating / fouling & over chilling/ too low suction pressure.& over chilling/ too low suction pressure.

-- optimum insitu cleaning to improve optimum insitu cleaning to improve regeneration efficiency. Save regeneration efficiency. Save water/chemicals toowater/chemicals too

PCRA’s Experience

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- Monitoring and adjusting cooling tower - Monitoring and adjusting cooling tower

for the rated for the rated range and approachrange and approach.. This This

alone controls the Discharge Pressure of alone controls the Discharge Pressure of

the compressorthe compressor

- Calculate regeneration efficiency in every- Calculate regeneration efficiency in every

shift. Aim for 90%shift. Aim for 90%

PCRA’s Experience

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In a Mirinda Orange Drink Plant found that it’s COIn a Mirinda Orange Drink Plant found that it’s CO22 absorption requirement was half compared to exotic Coco-absorption requirement was half compared to exotic Coco-Cola. Higher temperature of chilling for the desi drinks are Cola. Higher temperature of chilling for the desi drinks are enough. Different energy settings for different product mix.enough. Different energy settings for different product mix.

In a latex plant the OEM has set the chiller at +6 In a latex plant the OEM has set the chiller at +6 00 C of C of product temperature. The process needed higher product temperature. The process needed higher temperature of 16 temperature of 16 00 C! In operation, the product was shock C! In operation, the product was shock chilled and allowed to thaw!! A good example of energy chilled and allowed to thaw!! A good example of energy conservation at the interface of the equipment and process. conservation at the interface of the equipment and process. The machine needs reset for a product outlet temp of 16 The machine needs reset for a product outlet temp of 16 00 C. C.

PCRA’s Experience

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An FMCG major was connected from an An FMCG major was connected from an agricultural feeder. The voltage fluctuation agricultural feeder. The voltage fluctuation causing recurrent disruptions. They were causing recurrent disruptions. They were running DG sets at 20% load factor and running DG sets at 20% load factor and disconnected the EB feeder. Suggested lock disconnected the EB feeder. Suggested lock rotor protection/ re-acceleration after carrying rotor protection/ re-acceleration after carrying equipment wise no load / part load/ full load equipment wise no load / part load/ full load readings. The EB feeder was revived. DG set readings. The EB feeder was revived. DG set shutdown.shutdown.

PCRA’s Experience

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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? Amazing, is it not? Lot of low lying fruits!Lot of low lying fruits!

PCRA’s Experience

25.11.04 40

COMPANY POWER & FUEL

03-04 02-03

%

Ch

P&F/Tot Exp (%)

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

OPPORTUNINITES GALORE

Ref.Financial Express, Chennai 22.06.04

TOP 10 PRIVATE COS ACCORDING TO POWER & FUEL COST(Rs. Crores)

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WhoMoved

My Electricity?

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Individual Carbon NeutralityIndividual Carbon NeutralityDistributed Production for Distributed Distributed Production for Distributed

ConsumptionConsumption

Asymptote Nature?Asymptote Nature?

Production Engages

People + Locations

Ecological Degradation

Concepts for Future

But ………

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Food MilesFood Miles

Up-gradation / harvesting of low grade energy Up-gradation / harvesting of low grade energy sources (sun light, low temp.heat of flue gas sources (sun light, low temp.heat of flue gas from boiler, furnace, engines, low velocity wind from boiler, furnace, engines, low velocity wind by thermo compressors, heat pumps etc)by thermo compressors, heat pumps etc)

Awakening on Awakening on common property rightscommon property rights of air, of air, water, earth, sky….water, earth, sky….

Concepts for Future

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Conflict resolution between interest holders of Conflict resolution between interest holders of food, fibre, fodder, fuelfood, fibre, fodder, fuel

NPT on automobilesNPT on automobiles

Nuclear power for HNuclear power for H22 production / desalination production / desalination

Recycling industries for ferrous/ non-ferrous Recycling industries for ferrous/ non-ferrous metals, plastics, paper etc.metals, plastics, paper etc.

Concepts for Future

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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 AmbassadorsBrand Ambassadors of the of the FMCG, Media, Chartered Accountants etc. This FMCG, Media, Chartered Accountants etc. This will ensure sustainable business as well as lifewill ensure sustainable business as well as life

Concepts for Future

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ICAI published a book on energy audit and management.

Concepts for Future

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

Concepts for Future

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Save EnergySave Yourself

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