Resource Conservation at TTBG (Utilities)

1. Resource Conservation at TTBG (Utilities)

2. RESOURCES OF UTILITIES Water Resource Fuel Energy Power

3. Summary of improvements in Utility

4. Power Conservation at TTBG (Utilities)

5. Yearly KWH / MT Trend and 08-09 projection Projected KWH/MT is based on Apr -08 to Feb-09 Actual data KWH/MT There is continuous reduction in KWH/ MT except in 05-06 as there was expansion of the plant

6. Power conservation in Air compressors

7. Power conservation in Refrigeration

8. Power reduction in refrigeration system 2008-09 Power conservation in Refrigeration system Increasing refrigeration efficiency Reducing refrigeration requirement Maximum TR generation through VAM Increasing Efficiency of electrical chiller Optimize department condition Identify and stop conditioning of non critical area

9. Better June end Journey of continual power reduction in refrigeration system

10. Refrigeration Power consumption & Fresh air Enthalpy (Budget Vs Actual) Actual power consumption is less due to lower enthalpy • Maximum benefit in power saving will be during monsoon period. • Expected Saving for the year of 2008-09 is 20 Lac KWh Inspite of higher enthalpy ,the power cons is lesser .

11. Power conservation in other utility Areas Total Power saving achieved from above is at 1906kwh/day.

12. Fuel Conservation at TTBG (Utilities)

13. Reduction in Fuel consumption 2.5 KL/day saved due to TFH stoppage is included

14. Water Conservation at TTBG (Utilities)

15. Water conservation

16. Wayforward • Possibility of further reduction in power consumption in compressed air system • Optimization of use of air conditioning equipments • Possibility to stop cooling water return pumps in spinning

17. THANKS

18. Membrane Patented clip-in Joint Collar to avoid fold of membrane Diffused aeration system 2008-09 • In fine bubble diffused aeration, compressed air is released through 0.6 mm holes in diffuser lines placed just above the bottom of aeration tank. The rising bubbles transfer oxygen to the water, as well as transport bottom water to the surface. • While in surface aeration, water is rotating with the help of mechanical agitators, during this operation, only the surface water comes in contact with atmospheric air and absorbs oxygen. • The efficiency of diffused aeration system is high ( 17 % at 3.5 height ) whereas efficiency of surface aerator is ( 5% at same height) • This will replace 22 kw x 2 nos. surface aerator with only one 22 kw blower . • Expected saving in kwh/day :550

19. Air Compressor – G Trend With and Without inverter Without Inverter With Inverter SAVINGS OF 23 KW/HOUR WITH INVERTER

20. Water Conservation Plate and tube type reverse osmosis plant installed for treatment of waste and reutilized in process (Saving is approx 240 m3/day)

21. Problem faced during 2007~08 • Low VAM output :- • Low Hot water temperature • Low chilled water pressure in poly while VAM is operated (without electrical chillers) • Low chilled water return temperature as load shared by electrical chiller machine .

22. Tree diagram for increasing Refrigeration generation through VAM

23. Summary of actions to increase TR of VAM

24. Chilled water boosting pump Poly II Chilled water boosting pump Poly I PHE of steam condensate at VAM Return Chilled water line of Twisting air washer Plant-2 connected with VAM chilled water header

25. Schematic diagram of chilled water after implementation of improvement activity

26. Journey of continual power reduction in refrigeration system Improvement in VAM TR generation increased after implementation of improvement activities

27. Improvement in Electrical chillers Avg power cons per TR 0.73 (Area for improvement ) KWh/TR is high during Monsoon season due to high fresh air enthalpy

28. Tree diagram for reducing power consumption of electrical chillers

29. Action to reduce power consumption of Electrical Chillers

30. Cooling water distribution system UTILITY COOLING TOWER PROCESS COOLING TOWER – 1ST Nitrogen Plant Air Comp. A Air Comp. B Air Comp. C Air Comp. D Air Comp. E Air Comp. F Air Comp. G PROCESS COOLING TOWER – 2ND Chiller - A Chiller - B Chiller - C Chiller - D Chiller - E Chiller - F Dryer - A Dryer - B Dryer - C Dryer - D Dryer - E Poly-I Poly-II

31. Cooling water distribution system after first modification Stand-by UTILITY COOLING TOWER PROCESS COOLING TOWER – 1ST Close Nitrogen Plant Close Close Close Air Comp. A Air Comp. B Air Comp. C Air Comp. D Air Comp. E Air Comp. F Air Comp. G Close Modification was carried out for utilizing only one process cooling tower for both poly process PROCESS COOLING TOWER – 2ND Modification Chiller - A Chiller - B Chiller - C Chiller - D Chiller - E Chiller - F Dryer - A Dryer - B Dryer - C Dryer - D Dryer - E Open Open Poly-I Poly-II

32. Cooling water distribution system after second modification UTILITY COOLING TOWER PROCESS COOLING TOWER – 1ST Open Nitrogen Plant Close Close Open Air Comp. A Air Comp. B Air Comp. C Air Comp. D Air Comp. E Air Comp. F Air Comp. G Open Open Modification carried out in Feb’08 for utilising process cooling tower I for compressed air system and N2 system PROCESS COOLING TOWER – 2ND Close Close Modification Closed Chiller - A Chiller - B Chiller - C Chiller - D Chiller - E Chiller - F Dryer - A Dryer - B Dryer - C Dryer - D Dryer - E Open Open Poly-I Poly-II

33. Cooling water distribution system after third modification UTILITY COOLING TOWER PROCESS COOLING TOWER – 1ST Open Nitrogen Plant Close Air Comp. A Air Comp. B Air Comp. C Air Comp. D Air Comp. E Air Comp. F Air Comp. G Modification carried out In May’08 for Water and heat balance during operation of separate cooling tower for compressor & chiller PROCESS COOLING TOWER – 2ND Close Close Modification Chiller - A Chiller - B Chiller - C Chiller - D Chiller - E Chiller - F Dryer - A Dryer - B Dryer - C Dryer - D Dryer - E Open Open Poly-I Poly-II

34. With above improvement cooling tower approach reduced from 5 to 3 Improvement in cooling tower approach after modifications in cooling water distribution system UTILITY COOLING TOWER

35. Optimization of Utilities parameters * Microprocessor based control system installed at 2 chillers in place of electromechanical system Remarks: 1) Process conditions are established through planned experimentation at processes.

36. Identify and stop conditioning of non critical area

37. Improvement in Electrical chiller Avg power cons per TR 0.73 (Area for improvement ) KWh/TR is high during Monsoon season due to high fresh air enthalpy

38. Power conservation in Air conditioning Close Close Before After 2008-09 Modification in conditioned air distribution system of inverter room AHUs BothAHU in operation Only one AHU in operation

39. After Before close Power conservation in Boiler Area 2008-09 Modification in condensate transfer system CV in line Bothpumping station in line Only one pumping station in line

40. 2008-09 Schematic diagram of chilled water • Before expansion refrigeration load ~1600 TR (max. month avg.) • After expansion refrigeration load ~2800 TR ( max. month avg.) • VAM was installed and commissioned in 2006~07

41. Month-wise refrigeration requirement before & After of plant expansion 2008-09 • Data of 2003~04 & 2006~07 is taken for comparison as during above years refrigeration system (consumption) was stable :- • Year 2004~05 and 2005~06: Plant was under commissioning • Year 2007~08 : Refrigeration load was manually reduced due to water crisis and problem in chillers

42. Miscellaneous energy conservation projects carried out in Utilities : Saving : Power saving ~ 28 KW / Hr Power saving / annum ~ 2.5 lac Kwh Verifying the results