2. ENERGY CONSERVATION
• The quickest, cheapest and the most practical
method of energy savings.
• Energy is a manageable expense, and it can be
easily controlled through dedicated efforts.
• “communication, culture and commitment are
the key driving forces for us in making
‘conservation of energy a way of life’ at
our works.
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3. 8/1/2016 8:36 AM GSFC ltd. 3
• The latest is LED lighting . A 15 watt CFL can be
replaced by 7 watt LED . And the carbon
emission level is 8 gm /hr.
Ref- BEE EA text book
4. ENERGY MANAGEMENT STRATEGIES
1. Energy Conservation
If you don’t need it turn it
off.
2. Energy Efficiency
If you need it do it
more efficiently
6. About GSFC…...
• GSFC is an integrated complex for
manufacturing of Fertilizers,
Petrochemicals, Polymers, Fibers etc.
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• GSFC also have in built Co-Generation
system to make complex, self sufficient
for the need of power and steam.
• GSFC has installed capacity of 124 MW
of wind mill.
7. THE MAIN REASONS FOR HIGHER
SPECIFIC CONSUMPTIONS IN INDIAN INDUSTRIES
Obsolete technology.
Lower capacity utilization.
Casual metering and monitoring of energy
consumption.
Lower automation.
Poor raw material quality.
Poor handling, operating and maintenance
practices.8/1/2016 8:36 AM GSFC ltd. 7
8. AREAS IN WHICH ENERGY CONSERVATION
IS POSSIBLE
• Power
Pumps, compressors, fans, blowers
• Steam
Steam production & distribution network
• Natural gas
Furnaces
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9. COST OF ENERGY
• Power =Rs. 7.5 / kWh =
• Steam =Rs. 2720 / MT=
• Natural =Rs. 34 / SM3 =
Gas
NCV of Natural gas = 8400- 8700 Kcal/sm3
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8.7 Rs/1000Kcal
4.18 Rs/1000Kcal
4 Rs/1000Kcal
Enthalpy of steam = 650 Kcal/kg
10. Energy Management Cell, WBSEB
SECTOR WISE ENERGY CONSUMPTION
Type of Consumer Percentage of
Consumption
Agricultural 5
Industry 49
Transport 22
Residential 10
Others 14
Agricultural
Industry
Transport
Residential
Others
11. ENERGY SAVING OPPORTUNITIES IN STEAM
Desuperheating of steam
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P = 37 Kg/cm2.g
T = 350 0C
M = 40 MT/Hr
PCV
P = 20 K
T = 320 0C
Desuperheater
BFW
P = 20 Kg/cm2.g
T = 250 0C
M= 43.4 MT/Hr
Super heated steam acts as an inert gas and hence
reduces heat transfer coefficient.
Desuperheating resulted into more steam generation
by ~3.5 MT/Hr.
It can result into capacity limitation at higher load.
STH
13. THERMO COMPRESSOR TECHNOLOGY
• Useful when low pressure steam is being
vented / condensed.
• Requirement of medium pressure steam is
met by throttling high pressure steam.
• Higher pressure of MPS requires high
amount of HPS.
• Quantity of MPS determines recovery rate of
LPS.
• Very attractive pay back period.
• Becoming popular.
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14. POWER SAVING IN COMPRESSORS
• Provision of Inter stage coolers.
• Adequate CW supply to inter stage coolers.
• Clean heat transfer surface of Inter stage
coolers.
• Low inlet temperature of feed gas.
• Low temperature of cooling water.
• Less handling of inlet mass.
• Reduce the discharge pressure of
compressor if process permits
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15. power saving done in centrifugal compressor by
reducing discharge pressure from 11.5 kg.cm2
to 11 kg.cm2 .g
Power saving=1.73*11*4*0.9=68.5 kw
68kwh*7.5 Rs/unit= Rs 513 per hr
• BEFORE
AMP Drawn=54
• AFTER
AMP Drawn=50
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CASE STUDY- 1
POWER SAVING IN COMPRESSORS
15
17. CASE STUDY-2
POWER SAVING IN NH3 COMPRESSORS
• LESS HANDLING OF INLET MASS
• 24% NH3 solution preparation scheme:
• Liquid ammonia is supplied as refrigerant. Vapour
ammonia generated due to absorption of process heat
was supplied to Reciprocating vapour ammonia
compressors.
• Part of vapour ammonia absorbed in DMW to prepare
24% NH3 solution, which is required raw material in
Capro-Lactam plant.
• Resulted into less power consumption by compressors
due to reduction in loading step for Reciprocating vapour
ammonia compressors.
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19. ENERGY EFFICIENCY IN PUMPS
4. Trimming of impeller.
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1. Optimization of pumping system.
Following are the ways to improve performance and
there by to reduce power consumption.
3. Improving network system to reduce
pumping requirement.
5. Replacement of old and inefficient pump
with new and higher efficiency pump.
2. Installation of optimum size pump/motor
20. CASE STUDY-1-Trimming of impeller
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Liq NH3 to
consumers
P=~17 barg
P-601-A
Vap NH3 to Ref. comp.
MP
Flash
drum
LP
Flash
drum
NH3 storage
tank
L= ~2 Kms
VO = 5 %
Flow m3/Hr
Pressure barg
Power kWh
Imp.dia. mm
Design
82
07
35
325
Before
18
10.3
27
325
Recent
18
6.7
20
264
56
m3/Hr
P= 0.5 barg
Power saving =
0.56 lacs units /yr
(Rs. 4.2 lacs /yr
VO = 10 %
Liq.
NH3
LCV
21. CASE STUDY-2- Trimming of impeller
Case of proper capacity utilization
GSFC ltd. 21
FV-402-01
E-402-1 E-402-2 E-402-4
To T-402-1 (8.80
kg/cm2)
press= kg/cm2
P-404-1A/1B
FT-402-01
SKETCH FOR SUGGETION OF P-404-1A/1B
17.5
17 10
D-404-1
3.8
22. CASE STUDY-2-Trimming of impeller
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Impeller of the above pump trimmed & motor of the
pump replaced by 75 kw, earlier it was of 90 kw
Before After
Motor, kw 90 75
Impeller diameter,mm 355 340
AMP 100 90
power drawn(kwh) 64.6 58.2
Rs/kwh 7.5 7.5
RS 484.6 436.2
SAVING RS/Hr 48.5
SAVING RS/Yr 387693
23. Pump follows following equations after
Trimming of impeller(Affinity laws)
• Q2/Q1 = D2/D1
• H2/H1 = (D2/D1)^2
• P2/P1 = (D2/D1)^3
Where, Q = Flow in m3/Hr, H = Head in meters and
HP = power in kWh, D= impeller diameter
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24. CASE STUDY-3
Installation of higher efficiency pump
/ Improvement
in efficiencyCW circulation pump (P-012-1A/B/C),
Caprolactam-I Plant:
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• CW pumps were running since
commissioning of plant in 1974. Based on
survey carried out, pumps were found running
at very low efficiency -55 %
• New set of pumps installed having
higher head, capacity and better efficiency.
25. INSTALLATION OF HIGHER EFFICIENCY PUMPS..(CONT)
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6 meter
elevation
12 meter
elevation
18 meter
elevation
24 meter
elevation
From CT
basin
It is possible to
meet plant
requirement at
110 % load.
Pump ή = 55%
Pump ή = 80%
BEFORE
M= 5800 m3/Hr
H = 35 meter
P = 980 kWh
ή = 55 %
AFTER
M= 6800 m3/Hr
H = 40 meter
P = 990 kWh
ή = 80 %
Power cons/m3
circulation
Before = 0.169
After = 0.146
Booster
pumps
27. WHAT IS OUR ROLE?
Energy conservation becomes our
joint responsibility, be it the
industries, individual citizens,
organizations, oil companies, or the
government.
Each one of us has a specific and
significant role to play.
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28. CONCLUSION
∑(Little Ideas)= Big Result
∑(Wisdom + Effort) = Reduction of Energy
Cost Without Investment
Many Drops Make a
SHOWER
