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Energy Cost Reduction Study at

Energy Cost Reduction Study at. Draft Presentation 23-09-05. DSCL ENERGY SERVICES COMPANY LTD 2 nd Floor, Kanchenjunga, 18 Barakhambha Road, New Delhi 110001 Tel. 0091 11 23316801 Fax 0091 11 23319062. Contents. Accepted Energy cost reduction measures for implementation Status

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Energy Cost Reduction Study at

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  1. Energy Cost Reduction Studyat Draft Presentation 23-09-05 DSCL ENERGY SERVICES COMPANY LTD 2nd Floor, Kanchenjunga, 18 Barakhambha Road, New Delhi 110001 Tel. 0091 11 23316801 Fax 0091 11 23319062

  2. Contents • Accepted Energy cost reduction measures for implementation • Status • Way forward • Accepted measures but to be decided after trial • Energy cost reduction measures on ‘Hold’ • Way forward

  3. Summary of savings

  4. Accepted Energy Conservation Measures:

  5. Accepted Energy Conservation Measures:

  6. Accepted Energy Conservation Measures:

  7. Accepted Energy Conservation Measures:

  8. Projects on hold

  9. Projects to be decided after trials

  10. Long term projects – Cogeneration option

  11. Project-1: Installation of high efficient high capacity Boiler Feed Water Pump for CFB OBSERVATION Combined efficiency of 2 BFW pumps: 33% OPPORTUNITY Replacing these 2 pumps with a single high capacity high efficient pump. BENEFITS Power savings – 93 KW Annual savings – Rs. 31.5 lacs Investment – Rs. 5 Lacs (Including motor) Payback: : 2 months ISSUES: Hydraulic testing of the boilers SOLUTION Use the existing pumps during the hydraulic tests

  12. Project-1: Installation of high efficient high capacity Boiler Feed Water Pump for CFB STATUS Agreed, Pump specifications frozen and Enquiry floated SPECIFICATIONS PROCESS OWNER

  13. CFB-BFWP: Existing System Total flow: 33.8 cum/hr Discharge pressure: 56 kg/cm2 Suction pressure: 1.1 kg/cm2 Power:86.7 KW Design Eff: 55% Actual eff:33% Power:87.1 KW Design Eff: 55% Actual eff:33% Two pumps with a total capacity of 55.8 Cum/hr is operated. Design Efficiency of each pump: 55% Combined system efficiency:33% Opportunity for shifting to a single high capacity high efficient pump

  14. CFB-BFWP: Installation of efficient, bigger Pump New bigger sized pump Total flow: 33.8 cum/hr Discharge pressure: 56 kg/cm2 Suction pressure: 1.1 kg/cm2 Power:80 KW Design Eff: 70% The combined efficiency of both the pumps is 33%s Replacing these 2 pumps with a single high capacity high efficient pump . For hydraulic testing the old pump can be used. Power savings – 93 KW Annual savings – Rs. 31.5 lacs Investment – Rs. 5 Lacs (Including motor) Payback: : 2 months

  15. Project-2: Usage of Steam heaters instead of Electrical Heaters in power house for FO preheating OBSERVATION 184 kW electrical heaters are used for FO pre-heating at the power house OPPORTUNITY Electrical heaters may be replaced with steam heaters BENEFITS Savings in energy cost: 22 Lac Rs. Per annum Investment: Rs 10 Lacs (Investment to be revalidated taking into account automation sensors and other controls) Payback:5 months ISSUES: Investment to be revalidated

  16. Project-2: Usage of Steam heaters instead of Electrical Heaters in power house for FO preheating STATUS Agreed and already in touch with vendors for freezing the investment PROCESS OWNER DSCL ES Role Would revalidate the investment required and the cost benefit analysis

  17. Usage of Steam instead of Electrical Heaters in power house In the HFO Separator 72 kW Heaters (one standby) are used presently for heating of F.O. Booster Heaters are also of 72 kW(one standby) rating each. One Electrical Lube Oil Heater of 40 kW is also in operation.

  18. Usage of Steam instead of Electrical Heaters in power house Lube oil heater: A.C: 20.1 KW Actual consumption:45.2 KW A.C:30.1 KW Total Steam Requirement: 4.5 to 4.8 TPD Saving Possible: 22 Lac Rs. Per annum Investment: Rs 10 Lacs (Investment to be revalidated taking into account automation sensors and other controls) Payback:5 months

  19. Project-3: Installation of screen before crusher to reduce unburnts OBSERVATION 30 to 50% of coal fed into the crusher is –6 mm size and fines. More than 50% of coal fed into the boiler is less than –2 mm. Average unburnts in ash is 15% OPPORTUNITY Reduction of fines in coal by installing a screen before the crusher and reduction of unburnts in ash BENEFITS Coal savings – 43 kg/hr to 61 Kg/Hr Annual savings – Rs. 10.2 to 14.3 lacs Savings due to crusher load reduction: 5.2 KW Annual savings:0.48 Lacs Total savings: Rs. 10.7 to 14.8 Lacs Investment – Rs. 5 Lacs Payback: 5.6 month

  20. Project-3: Installation of screen before crusher to reduce unburnts ISSUES: Nil STATUS Agreed and already quotation for the screen has been obtained PROCESS OWNER

  21. Installation of screen before crusher to reduce unburnts 10*10 cm 53.3% 37.2% Requirement: (-)6 mm to +2mm Rejects 25.9% 25.4% 8*8 mm 5 mm sieve 5.1% 33.4% 44.1% 32% As per samples taken on 19th & 20th

  22. Installation of screen before crusher to reduce unburnts 22.48% 10*10 cm Rejects 43.03% Requirement: (-)6 mm to +2mm 0.85% 8*8 mm 2 mm sieve 63.2% As per samples taken on 14h & 20th Unburnts increase because of fines. Provision of screens at the Inlet to hammer mills.

  23. Installation of screen before crusher to reduce unburnts 6*6 mm screen Proposed scheme Possibility of maintaining the fines from 5 to 10% in imported coal

  24. Installation of screen before crusher to reduce unburnts • Sample size: 1.5 kg • Average fines (-2mm) in raw coal : 18.8% • Average fines (-2mm) to coal bunker: 60% • - 2 mm sieve coal increases from 18.8 units to 60 units • Avg unburnts in ash: 15.47% Unburnt % variation 25% of the total fines generated at crusher Limit fines Generation at crusher by installation of screen at inlet to the crusher. This Will help reduce the unburnts in ash and reduce power consumption at the crusher Maintaining unburnts from 5 to 8% Coal savings – 43 kg/hr to 61 Kg/Hr Annual savings – Rs. 10.2 to 14.3 lacs Savings due to crusher load reduction: 5.2 KW Annual savings:0.48 Lacs Total savings: Rs. 10.7 to 14.8 Lacs Investment – Rs. 5 Lacs Payback: 5.6 month

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