By
Kiran R Patil
Under the guidance of
Sri B. Aprameya SwarupAsst. ProfessorS.J.C.E, Mysore
IntroductionEnergy the prime mover
For the progress of any countryAny industryAny sector
Rising costs of new generating plants has led toFinancial constraintsDifficulty in production of electrical energyHigher energy bills
Cont…….Generated Energy has to be used
EfficientlyReduce the energy consumptionReduce the losses by end users
For many companies energy is the significant operating cost
Bills of 1.5crores through 2crores are not uncommonFlour milling is one of the largest energy intensive industry after raw material costsBut, energy is the most controllable production costs.
Cont…….We cannot reduce man power by fractions but we can achieve significant savings by reduction in energy consumptionsConsider the flour mill
The energy billing is high and penalty is also highEnergy is the direct charge on companies operating budget“Every 1 unit saved is equal to 2 units generatedReducing energy bills accrues an increase in bottom line profit Improved electrical efficiency is the key to saving energy in any industry or flour mills
Concept of Energy Audit
Why Energy Audit?To reduce the cost of productionTo identify areas of excess energy consumptionTo suggest ways for minimizing energy consumption
Indicative Saving PotentialGood house keeping - 5 - 10%Minor investment - 10 – 15%Reasonable investment - 20 – 25%
Methodology AdoptedUnderstanding the process of the millInspection and Data collection of machineriesObservation on general conditions
FacilityEquipmentQuantification
Month wise energy consumption and production data from financial year April 2006 through March 2010Identifying and verifying the major energy consumption areasDiscussions with electrical and production personnel to make necessary arrangements to take measurements
Cont…….Measurement of electrical parameters like voltage, current, power factor, kW, kVA, kVAr, Hz and Harmonics on all identified motors
Detailed calculations, analysis and assumptions
Validation from the electrical personnel and energy auditor
Identify the potential energy saving area and analyzing the saving proposals with plant personnel
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Main processesWheat reception and storage
Cleaning and conditioning
Milling and sieving
Blending, flour storage and packaging
Annual energy consumption in C-mill19,11,222.41 units out of 46,58,530 units
Annual demand chargesRs. 16,47,900/-
Energy cost @ Rs. 4.65 per unitEnergy cost this year
Rs.1,98,24,457+ Rs.10,73,617.875 taxEnergy bill (app.) Rs. 16,52,038.1/monthSEC in a month( app.) 58.145kWh/tonEC kWh/Ton per day - 2.32kWh/tonAverage power factor maintained 0.97
Energy scenario
Energy consumption in kWh from April 2006 – March 2010
0
50
100
150
200
250
300
350
400
450
500
2006 2007 2008 2009
Financial year
Total kWh
C-mill kWh
Lighting kWh
other electronic goods kWh
mil
lion
unit
s
Energy bill and demand charges from April 2006 - 2010
0
20
40
60
80
100
120
140
160
180
200
Energy Cost C mill Energy cost
Tax Demand charge
2006
2007
2008
2009
Rupe
es i
n C
rore
s
Cost of Sections
Monthly peak demand from April 2009-March 2010
0
100
200
300
400
500
600
700
800
900
MD
Rea
ched
in k
VA
Break up of energy use
Milling and grinding 44%
Pneumatic conveying 32%
mechanical conveying 9%
Compressed air7%
Particle separation 5%
Services 3%
Factors governing Energy useWheat quality
Impurities, moisture content and quality of wheat
Product qualityNeed for blending and wheat products
Mill loading
Atmospheric conditionsHumidity, temperature and pressures
Operation schedule of machinesSection Wise HP
Wheat Cutting to A-Mill Silos 44
A-Mill Silo to C-Mill 22.5
Washing 103.75
Tempering 13.5
B1 Petty 26.5
General Exhaust for Dust 17.6
Refraction Grinding 69.5
Grinding section 421
Redressor section 34
•Washing section: 17 hours per day
•Other Sections: 21 hours per day
Need of determining motor load and efficiency
Motor accounts for more than 80% load in a plant
Motors are mismatched or oversized for particular load
Motors might have rewound multiple times
So To compare the operating costs of an existing standard motor And replace with appropriate sized Energy Efficient motorMotor load and efficiency is to be determined.
Constraints of energy AuditingNo proper information
No real time data
Energy Auditing is based on the principle of“We cannot manage, what we don’t measure”
One time energy auditing is not sufficient
No continuous monitoring
Monitoring & TargetingIt is a management technique which helps to
Control energy consumption
Control any resource
Continuous monitoring
Gather continuous information
Indicate the continuous varying pattern“Without Compass and Map we are dead men in the Desert”.
Installation of Monitoring System
800kVA
Smart server or Data concentrator It is used to
Control
Monitor
Manage any electronic device
Remotely access data
Manage the entire control system
Energy Nodes and Sensor gatewayEnergy meter which helps in collecting around 10 electrical parameters for R, Y, B phases
Voltage, current, powerActive power, Reactive powerFrequency, power factorPlots the load variations for the connected machines
Sensor gateway gives the physical parameters
Pressure, Temperature, Flow
How the monitoring system worksConsidering the Smart Server
Two types of internet protocolsStatic internet protocolDynamic internet protocol
Static internet protocol is used to access local works either for LON or the LAN
Dynamic Internet protocol is used to access globallyExample Broad Band
Cont…….
Motor (Blower Fan)
Compressor
Electrical Panel
Sensor Gateway
Energy Node
Smart Server
Personal Computer
Cont…….A particular machine
Motor or Compressor connected to energy meter or sensor gateway respectively through electrical panel.
Panel is connected to Smart Server
Smart Server is connected to PC to access data
Connections are done through communication cable Communication cables are used to inter connect server and machines as well.
Cont…….PC should be installed an application called as OPIUM energy
This helps in accessing data
Plotting the graphs automatically
Smart Servers can be used as occupancy sensorsThe application can be used
To Control lighting system
To Control Fans and other electronic goods which saves energy
Advantages of Monitoring and TargetingExpected Benefits
Guidance to reduce excess energy consumption
Identify the default equipments
Power factor improvement
Current reduction and reduction in line losses
Load balancing and minimizing of neutral current
Maintaining SEC and creating bench marks
Determining the future energy use when planning changes
Diagnose specific areas of wasted energy
Energy saving proposal 1
Investment = Rs. 3,50,000/-Annual energy consumption = 19,11,222.41 kWh
Expected savings through EMS @ 5 – 15% but assuming= 95,561.12 kWh
Annual cost savings @ 4.7/unit = Rs. 4,49,137.264/-
Pay back period= Investment/ annual savingsRs. 4,00,000/4,49,137Approximately 10 months 18days
It is worth to invest in this monitoring system
Investment on energy monitoring system
Energy saving proposal 2Conversion of Delta to Star
For lightly loaded motors (Below 50% Load)In Delta: 10 hp Motor, 7.26kW, operating hours 16In Star: 6.55kW, operating hours 16Difference in kW 0.71kW, 0.71*4800 h = 3408 kWh
Similarly, 7.5 hp, saved energy = 4416 kWhFor, 5hp, saved energy = 1344 kWh
Annual savings: 3408+4416+1344+1836 = 11004 kWhAnnual cost savings @4.7/unit =Rs.51,718.8/-Investment nilPayback period immediate
Load variations are common in flour milling industries
Considering the 10 hp motor Rated speed = 1440 rpm
This motor is operated at less speed due to requirementReducing speed up to 1100 rpmCannot be achieved by reducing the pulley size
Therefore the VSD is used in order to quantifyEnergy savings and reduce the losses
Energy saving proposal 3Installation of Variable Speed Drive
Cont…….Energy consumed without VSD = 6.323 units/hour
Energy consumed with VSD = 3.670 units/hour
Difference in Energy consumption = 2.653 units/hour
Total annual Energy savings by VSD
= 2.653 * 16 * 300
=12,734.4 units/year
Annual cost savings@ Rs.4.7/unit = Rs. 59,851.68/-
Approximate investment required = Rs. 65,200/-
Payback period = 13 months
Replacement of existing Less efficient motors by Energy Efficient motors
Replacement model is concerned with replacementMachines and Equipments
Replacement is done dueTo their decreasing efficiencyFailuresBreakdown of equipment partsLow performance
This model helps us to findOptimum replacement periodOptimum cost
Cont…….There are two types of failures
Gradual failure
Sudden failure
We are concerned with gradual failure which includesGradual decrease in the efficiency of equipmentsIncreased maintenance(operating and running costs)Decreased productivityDecrease in resale value which represents the depreciation
Calculation of optimal replacement period
Optimal replacement periodAverage cost incurred from the time of the implantation of the machines
Money value has been taken into accountPresent Value Factor (PvF) = 1/(1+r)(N-1)
Where ‘r’ is the discount rate (the rupee value depreciates at a constant rate i.e. 9%(standard))
‘N’ is the number of years
Replacement of 50 hp motor
Energy saving proposal 4Replacement of less efficient to EEM
Cont…….Total Annual Energy Savings
18 hours motor operation for 300 days per annum= 10 kWh * 18 * 300= 54000 kWh
Annual cost savings @4.7 = Rs. 2,53,800/-Price of Energy Efficient motors obtained from M/s Siemens Ltd. Is given below
10 hp, 6 poles = Rs. 32,640/-15 hp, 6 poles = Rs. 40,570/-15 hp, 4 poles = Rs. 31,640/-20 hp, 6 poles = Rs. 58,270/-30 hp, 2 poles = Rs. 87,990/-
Cont…….Investment required for 10 number of EE motors
= Rs. 32,640 * 4= Rs. 40,570 * 3= Rs. 31,640 * 1= Rs. 58,270 * 1= Rs. 87,990 * 1
Total cost = Rs. 4,30,170/-
Payback Period = 20 months
Advantages of Energy Efficient Motor
Saves Energy and Money
Covers up to uniform Efficiency from 50% - 100% of full load
Ensuring savings at part load conditions also
Short Payback period
Substantial savings after Payback Period
RecommendationsReduce system load e.g. by using more efficient fan
Minimizing the amount of air used by pneumatic systemsReducing leakages from compressed air systemsReducing pressure drops in pneumatic and compressed air systems
Improve maintenance schedule and proceduresSwitch of when idling
Soft starters can be usedEnsure that motor is not oversized for the jobReduce motor losses
Replace with energy efficient motorsIf repaired or rewound, ensure efficiency losses are minimized
Cont…….Reduce motor running speed by using variable speed drives
Advantages includeSignificant cost savingsAutomatic or manual controlVersatilityReliability
Use Multi speed Motors (MSMs)Can be used when two or more speeds of operation, particularly effective if speeds are carefully matched to the characteristics of fan
Operate at full load for shorter periodsOperate with a high loading to maximize efficiency
Cont…….Lighting systems connected to the Smart servers act as occupancy sensors which controls the lighting circuitsMaximum demand charges can be reduced by managing the load at peak timesThe whole mill is inter connected to one another
if one machine shuts off complete mill should be shut downseparate connections to separate sections of the machinereduces high amount of Maximum demand charges.
RefurbishmentsKeep conveying and transfer routes as short as possibleMinimize transfer distances for wheat and flour
so that each processing area is next to the previous one
Minimize the number of lifts of wheat and stock
Copper catalyst at the end of the exhaust of general dust exhaust minimizes the effect of dust to the environment
Install the process control and monitoring equipment
Cont…….
Summary
Future Scope
Cont…….
Bloom Energy is a solid oxide fuel cell server
Uses solid, liquid or gaseous fuel
It produces electricity which is cleaner form of energy
If used renewable fuel form of energy,
It is more cheaper and more cleaner form of Energy
Cont…….This solid fuel cells can generate 100kW through MW of Electricity
Fuel cell converts Hydrogen, Natural gas any fuel to electricity
This is an “ELECTRO-CHEMICAL PROCESS”
The bloom energy is 67% clean if used hydrocarbon fuels
If renewable fuel cells are used, 100% clean and cheaper energy can be produced and used which is abundant
ReferencesEnergy Auditing concepts of M/s Kovilpatti Lakshmi roller Flour Mills Ltd. Gangaikondan (Tirunelveli), Energy Audit conducted by, Central Scientific Instruments Organization, CSIR Madras complex, Govt. of INDIA.
Guide Books for the National Certificate Examination for Energy managers and Energy Auditors (set of four books available at http://www.energymanagertraining.com/new_course.php)
J.C. Andreas, Energy Efficient Motors. Marcel Dekker publication, New York1992
Cont…….Good practice guide 212 for improving Energy Efficiency and reduce Energy costs in Flour Milling, Energy Efficiency enquiries Bureau, Oxfordshire, UK.
Typical performance data of premium Energy Efficient (EE) Motors and standard motors from Bharath Bijlee Ltd. Motors for general applications.
Official Website of the Bureau of Energy Efficiency, Govt. of INDIA, www.bee-india.nic.in
Quick start guide to Energy Monitoring and Targeting (M&T), www.oursouthwest.com
Detailed information and case studies on energy audits, www.energymanagertraining.com
Energy monitoring and targeting (M&T), www.mt.wikipedia.org/wiki/monitoring_targeting
The energy conservation act, 2001, http://powermin.nic.in/acts_notification/energy_conservation_act/index.htm
Cont…….
www.en.wikipedia.org/wiki/energy_audit
Website of Ministry of Power, http://powermin.nic.in/energy_audit
“Bloom Energy” – What is it and how does it works? http://peswiki.com/index.php/Directory:BloomBox_Fuel_Cell_by_Bloom_Energy.
Cont…….