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Low Carbon Energy Use in SMEs and Larger Industrial Establishments : Some Cases From India

Dr. Binoy K Choudhury Indian Institute of Social Welfare & Business Management (IISWBM) Conference on Low Carbon Energy for Development: Past Experiences and Future Challenges Loughborough University, UK.

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Low Carbon Energy Use in SMEs and Larger Industrial Establishments : Some Cases From India

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  1. Dr. Binoy K Choudhury Indian Institute of Social Welfare & Business Management (IISWBM) Conference on Low Carbon Energy for Development: Past Experiences and Future Challenges Loughborough University, UK Low Carbon Energy Use in SMEs and Larger Industrial Establishments: Some Cases From India

  2. SECTORAL SHARE OF COMMERCIAL ENERGY CONSUMPTION IN INDIA (MTOE) (2007-08) TOTAL = 272.4 MTOE

  3. INDIAN ENERGY USE Coal, oil and natural gas together account for more than 95% of India’s primary energy supply (excluding biomass), whereas the share of hydro, nuclear, and other renewables is less than 5%.

  4. India – Potential for various Renewable Energy Technologies by 2020 Of the total potential of 183,000 MW, installed capacity of grid-interactive & off-grid power by March 2011 was 20492 MW, amounting to only 11.2% [RE Potential > Overall Total Installed Capacity]

  5. GHG Emissions Distribution (MT CO2-eq) Across Sectors (2007) TOTAL = 1398.7 CO2 eq

  6. INDIAN ENERGY SAVING POTENTIAL A recent study by the World Resources Institute (WRI) India’s energy demand is expected to become more than double by 2030. The country is consequently in need of a huge amount of new power generation capacity. Considering the figures of the WRI, the cheapest generating capacity for India will no doubt be energy savings. The savings potential is estimated to vary from 20% to 50%.

  7. ENERGY USAGES & LOSSES Energy Losses Energy Losses Energy Losses Causes of Losses • Supply chain Management (handling and storage) • In-efficiency of Conversion • Technology • Maintenance Practice • End Use In-efficiency • Lack of New Technologies • Lack of Energy Modesty • Interdisciplinary Issues • Administration • Policy • Tariff, Cost Control • Alternative Fuel • Renewable • CDM • Energy Certification • Ministries/Depts Involved • Planning Commission • Power • Petroleum & Nat. Gas • Coal • MNRE • Dept of Atomic Energy

  8. BENEFITS OF ENERGYCONSERVATION Investment - Only a third compared with Capacity Addition Low Carbon Option (as Burning of Fuel is not Required) Savings of Foreign Exchange as India Imports about 34% of the total Energy Resources Used Social Issues (Earth with Resources are Borrowed from Future Generation) Environmental Issues (reduces pollutant emissions) National Energy Security Option

  9. ENERGY CONSERVATION MEASURES CASE 1 : Supply Chain Management Control - Carpet Loss & Rain Water Protection • One of the Leading Electricity Supply Company Could Reduce the Maintenance Cost in the CHP by Constructing Rain-water Shed to the Tune of GBP 3 million/year Besides Efficiency Improvement of the System. • Total Investment was GBP 3 million (One Time) Only. • Thus the Pay-back Period Is Around One Year.

  10. ENERGY CONSERVATION MEASURES CASE 2 : (Process) Energy Efficiency - Air Infiltration – Excess Air Issue : At BANDEL THERMAL POWER STATION

  11. AIR & FLUE GAS (FG) PATH GENERATION: 55MW DATE:17.10.06 ECO INLET (FG) 0 Temp. ( C ) 400.6 O % 1.9 2 CO % 17.0 2 COAL CO OOR 25.4% Ash Flow 259.6 35.13 T/hr WATER OUT 5266 Kcal/ Kg ECO WATER IN ECO OUTLET (FG) 0 Temp. ( C ) 336.1 /APH INLET(FG) O % 3.4 2 APH CO % 15.9 2 CO 637.0 Flow 278.5 APH INLET APH OUTLET ESP INLET (FG)/APH OUTLET ESP OUTLET (FG)/ID INLET 0 0 0 0 Temp.( C ) 32.4 Temp. ( C ) 282.5 Temp. ( C ) 177.5 Temp. ( C ) 139.4 O % 21 O % 20.9 O % 6.8 O % 10.735 2 2 2 2 Flow 226.3 CO % 0 CO % 12.8 CO % 0 2 2 2 CO (ppm) 6.7 CO 7971 CO OOR Flow 336.5 Flow 446.5 Note: Assumtions: Air :Coal (Stoiciometric) = 5.8 OOR Out Of Range Excess Air= O X100%/(21-O ) 2 2 Acuracy Upto 1st decimal place Fly Ash in Total Ash = 80% ID ESP FD

  12. Generation 55 MW Date: 17.10.06 Power Loss in ID Fan due to Infiltration of Air/Gas Coal Burning Rate 35.13 T/Hr Stoichiometric Air Coal Ratio 6 Stoichiometric Air 205.44 T/Hr Excess Air Allowable for Complete Combustion= 21.00% of Stoi.Air Excess Air Allowable to Consider Infiltration in Economiser and APH, as per design= 2.00% of Stoi.Air Excess Air Allowed in ESP (assumed) 2.00% of Stoi.Air Desirable Flue Gas Flow at ESP Outlet, as per design 283.01 of Stoi.Air Excess of Excess Air (Actual - Desirable)= 163.49 T/Hr Reduction in Flow, if there were no excess of excess air= 36.62% Reduction in Consumption of Power (Ref. BEE Book 3, p98)= 15.63% Actual Power Consumption in ID Motor = 779 kW Saving in ID Fan Power, if there were no excess of excess air= 121.72 kW Plant Operating Hours = 3200 Hrs/Annum Electrical Energy Saving = kWh/Annum 389,500 BTPS Electricity cost (Rs/kWH) GBP/kWh 0.022 Annual Monetary Saving = 8,466 GBP/Annum Resulting Reduction in Plant Auxiliary Consumption = 2.21%

  13. EXECUTIVE SUMMARY – BTPS UNIT # 4 & COMMON AREAS TOTAL CO2 REDUCTION BY ABOVE = 18765 Ton/Year

  14. ENERGY CONSERVATION MEASURES CASE 3 End Use : Power Generation Potential From Blast Furnace Gas • BLAST FURNACE AREA • Recovery of B.F. Gas • Improved Automation of Hot Blast Stove • Utilities- Pumps, Fans, Compressor, Conveying Systems • and Cooling Towers - Energy efficiency improvements

  15. CASE STUDY : IRON & STEEL INDUSTRY (300 Mta) Estimated CO-GENERATION FROM FLARED BF GAS: Savings per annum GBP 6.43 million Estimated investments GBP 11 million Simple pay back 21 months ROI – 52.27%

  16. CASE 4 : ENERGY EFFICIENCY MEASURES At Howrah Galvanizing and Wire Drawing Industries

  17. Definition of MSMEs in India

  18. Profile of Indian SME Sector

  19. List of BEE SME Energy Efficiency Programme Clusters Contd ..

  20. Contd ..

  21. Contd ..

  22. TECHNOLOGY : ENERGY EFFICIENCY MEASURES Process flow diagram after project implementation :Air Pre-heater for Galvanizing and Annealing Furnaces Installation Of Air Pre-heater

  23. TECHNOLOGY : ENERGY EFFICIENCY MEASURES Case study : Installation Of Air Pre-heater In Howrah Galvanizing And Wire Drawing Industries

  24. Case study : Using Biomass Gasifier instead of Furnace Oil/Coalin Galvanizing of Howrah Cluster

  25. Case study : Installation Solar Water Heaterin Solahpur Cluster

  26. Estimated Total Saving, Investment & CO2 Reduction of Howrah Cluster

  27. TECHNOLOGY : ENERGY EFFICIENCY MEASURES CASE 5 : VAM : AT AN UNIVERSITY CAMPUS (BESU) • TOTAL ELECTRICAL LOAD : 850 KVA • TOTAL CONNECTED COOLING LOAD : 354 TR • 14 HOSTELS WITH 100 STUDENTS IN EACH : 1400 STUDENTS LIVING IN CAMPUS • PROPSED COGENERATION SYSTEM : TRIGENERATION – POWER, HEATING AND COOLING • PROBABLE INVESTMENT (GBP): 508,572 • ESTIMATED ANNUAL SAVING (GBP/Yr): 161,568 • SIMPLE PAY BACK (Yr) :3.15 • ROI (%/Yr) : 26.77

  28. SUMMARY : SIMPLE SOLUTIONS • Energy Modesty • Education & Awareness • Training & Capacity Building • Upcoming Technologies: VAM, Heat Pump, CHP, Smart Grid, PMM, etc. • International Collaboration • ISO 50001

  29. IISWBM’S ENERGY MANAGEMENT INITIATIVES….SINCE 1993 37 • Awareness, Seminar and Training • Full time course – two years Master Degree Energy Management in MPSM Programme under University of Calcutta • Short term course – three months short term course on Energy Management & Audit • Energy Club & AEE – India Chapter • Energy Research & Consultancy Projects

  30. ACKNOWLEDGEMENTS: IISWBM, LOUGHBOROUGH UNIVERSITY, LCEDN, REFERRED BOOKS, WEBSITES Questions? Email Please: bkchoudhury@iiswbm.edu binoykchoudhury@gmail.com THANK YOU

  31. Thank you ON BEHALF OF ENERGY MANAGEMENT DEPARTMENT OF INDIAN INSTITUTE OF SOCIAL WELFARE AND BUSINESS MANAGEMENT www.iiswbm.edu phone : 2241 3756; fax : 2241 3975 SUSTAINABLE ENERGY AND GHG ACCOUNTING CELL ASSOCIATION OF ENERGY ENGINEERS - INDIA CHAPTER www.aeeindia.org

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