The Efficiency Solution

Rangan Banerjee Energy Systems Engineering IIT Bombay

National Seminar on Energy Solutions, Bhopal, May 15,2004

Outline of Talk
Dimensions of the Energy Problem
India- Energy Situation,Fossil Fuel Reserves Energy flow diagram Electricity Sector Energy-Emissions Linkage Need for Energy Efficiency

The Efficiency Solution

Commercial Energy Supply in India (1997-98)

Source Coal Oil(D) Imports Nat Gas Hydro Nuclear Total Supply 307 Mt Cal value 18.8 MJ/kg 41.MJ/kg PJ 5775 1415 2108 1026 311 151 10787

33.86 50.43 26.4 Bm3 9300 73500 MU 85% eff

10500 MU 25% eff

India- Overall Energy

Population 966 million in 1997-98 13840 billion Rs (000 Million) GDP 10.8 EJ (258 Million tonnes of oil equiv) 11.2 GJ/capita/year (0.27toe/capita/year) Per capita GDP =Rs 14,300 ($360) Energy/GDP = 0.75 kgoe/$

India- Primary Commercial Energy

Hydro 3% Nuclear 1%

1997-98 Total 10,800 PJ

Coal 53%

Oil Import 20% Oil (D) 13% Gas 10%

10.8 EJ

Biomass Estimation
Uncertainties in estimation Usage Domestic, Brick kiln, rice mills, other industries Per capita Biomass use approx constant over last 20 years 6.4 GJ/capita/year (Joshi et al) 6180 PJ 1997-98 Total 17 EJ (4% of World) Population 16.9% of World

India - Fossil Fuel reserves

Fuel Coal
(Million Tonnes)

Reserves Prodn R/P ratio 60000 296 ~200+ 660 692 33.86 19 (9) 26.4 26 ~50
Data Source TEDDY

Oil
(Million Tonnes)

N.Gas
Billion m3

Nuclear Nat U

Primary Energy Use by region (1997)

300

250

GJ/capita/year

200

150

100

50

North Latin America America

OECD Europe

NonOECD Europe

Former Soviet Union

Middle East

Africa

China

Asia

Pacific OECD

1997-98

1997-98

Electricity Sector in India

Low per capita electricity consumption (~400 kWh/capita/year) Energy and Peak power scarcity Large number of villages un- electrified Significant proportion of households without access to electricity Electricity use linked with quality of life

Share of Power Installed Capacity (1998) in India

Diesel 0.4%

W ind 1.0%

Nuclear 2.5%

Gas 8.7%

Hydro 24.6%

Coal 62.7%

Nuclear Power
India 2720 MW- RAPS 100+200+ 2220 MW Kalpakkam (TN) 2 170 MW Narora (UP) 2 220 MW Kakrapara (Gujarat) 2 220 MW Kaiga(Karnataka) 2 220 MW Tarapur (Maharashtra) 2 160 MW 0.7% of World Nuclear Capacity

Installed Capacity of Renewables in India

1600 1400 1200 1000 800 600 400 200 0
W

1267

1341
Total Renewable Installed capacity 2978 MW 31/3/2001 MNES

210 63
lH yd ro bn C og en in d s

35
gy

15
rP V So la

47

er G W as ifi

Bi o

Bi o

al

as te

Sm

-E ne r

C om

India - Electricity Sales

350000 300000

Electricity Sales (GWh)

250000

200000

150000

100000

50000

1950

1960

1970

1980

1990

2000
S

Year

Annual Capacity Additions

6000 5000
Capacity Addition (MW)

4000

3000

2000

1000

0 1960 1965 1970 1975 1980 Year 1985 1990 1995 2000

500

400

Electricity Generation('000 GWh)

300

200 To ta l 100 H y d ro

0 1960

1970

1980

1990

2000

Year

Electricity
104 GW Installed Capacity 2002( less than 4% of World Capacity) Average 0.1 kW of installed capacity/capita World installed capacity 0.53 kW/capita Low electricity consumption Indiaabout 340 kWh/capita/year Nepal, Bangladesh & Bhutan lower than 100 kWh/capita/year World average electricity consumption2100 kWh/capita/year

Electricity Sector
SEB annual loss 2000-1 Rs 20,500 crores . Gap of 92 p/kWh - between cost of supply and revenue Peak shortage 13%, energy shortage 7% Estimated requirement of 100,000 MW additional capacity by 2012

Load curve of a typical day MSEB

(8/11/2000
source: WREB annual report-2001)

11000
Demand, MW

10260 MW 9892 MW

10000 9000 8000 7000 6000

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
morning peak
Evening peak

Time hours

Energy Consumption and Air Pollution

SO2 NOx CO SPM CO2 CFC Modification of Atmospheric properties/processes Photochemical Smog Precipitation Acidity Visibility Corrosion Potential Radiation Balance Alteration Ultraviolet energy absorption

Source : Energy After Rio: UNDP Publication.

Environmental Impacts
Adverse Health Impacts- Local Local perturbations to Global Disruptions as human energy use increased Human Disruption Index (DI) = Ratio of Human generated flow of a given pollutant to the natural or baseline flow

Carbon Dioxide Concentrations

Carbon Dioxide Concentrations

Carbon Dioxide Emissions

Kaya identity: Total CO2 Emissions = (CO2/E)(E/GDP)(GDP/Pop)Pop CO2/E Carbon Intensity E/GDP- Energy Intensity of Economy Mitigation increase sinks, reduce sources- aforestation, fuel mix,energy efficiency, renewables,nuclear, carbon sequestration Adaptation

GHG Emissions (Fuel Cycle Analysis)

CO2 g/kWh Coal Conventional 960 -1300 Advanced Coal 800-860 Oil 690-870 Source: John Holdren Gas 460-1230 Kirk Smith, World Energy Nuclear 9-100 Assessment, UNDP,2001 Biomass 37-166 PV 30-150 Hydro-electric 2-410 Wind 11-75

Issues /Comments
Fossil fuel depletion -oil-gas-coal (finite time period ~100 years) Low energy service per capita, High Growth Energy and Quality of Life Sustainable Development Meets the needs of the present without compromising ability of future generations to meet their needs Present Consumption patterns unsustainable Need for Alternatives Clean, Renewable

Need for Efficiency

Renewables In general , not yet cost-effective Capital Scarcity- Payment Crisis of Subsidised Energy Sectors Gestation Period for New Power plants Least Cost Planning Energy Efficiency Transition fuel

ENERGY FLOW DIAGRAM

PRIMARY ENERGY

COAL, OIL, SOLAR, GAS POWER PLANT, REFINERIES REFINED OIL, ELECTRICITY RAILWAYS, TRUCKS, PIPELINES WHAT CONSUMERS BUY DELIVERED ENERGY

ENERGY CONVERSION FACILITY

SECONDARY ENERGY

TRANSMISSION & DISTRN. SYSTEM FINAL ENERGY

AUTOMOBILE, LAMP, ENERGY UTILISATION EQUIPMENT & SYSTEMS MOTOR, STOVE

USEFUL ENERGY END USE ACTIVITIES (ENERGY SERVICES)

MOTIVE POWER RADIANT ENERGY DISTANCE TRAVELLED, ILLUMINATION,COOKED FOOD etc..

Energy End Uses

End Use Energy Service Device

Cooking Lighting Transport

Motive Power

Food Cooked Illumination Distance travelled Shaft work Fluid heated

Chullah, stove Incandescent Fluorescent, CFL Cycle, car, train, motorcycle, bus motors Boiler, Geyser

Cooling Heating

Space Cooled Fans,AC, refrig

Importance of Energy Conservation

Energy Conservation Act 2001 Setting up of the Bureau of Energy Efficiency (March 2002) Standards and Labelling Energy Conservation Fund Designated ConsumersEnergy audits by accredited auditors Certified energy managers Norms and standards of energy consumption

Energy Cost in Chemical Industry

12% of manufacturing cost. Real growth in energy bill higher than real growth in raw material, sales. Higher energy prices competitive disadvantage (compared to US, UK, Brazil, France) Electricity accounts for 44% of fuel mix. Electricity price increasing at higher rates than other fuels (10% per year real growth).

EC Company Policy
Many companies declared EC policy , in response to a request by Energy Management Centre for example Reliance : Our mission is
to be the lowest specific energy consumer in the industry we operate in To maximise the use of renewable fuels and low energy level fuels in our operations Mukesh Ambani

Energy Conservation Opportunities

Design Stage
Efficient process design Efficient equipment design/ selection Efficient Utility System design

Operating DecisionsEnergy Auditing Operating Strategies Retrofit equipment Replace equipment/processes

What is an energy audit?

Audit financial connotation examination with an intent to verify Energy audit coined in the 70s after the oil shocks An energy audit is a study of a plant or facility to determine how and where energy is used and identify methods for energy savings

DEFINE AUDIT OBJECTIVES

QUESTIONNAIRE

REVIEW PAST RECORDS

WALK THROUGH / PLANT FAMILIARISATION

DATA REQUIREMENTS DATA ANALYSIS MEASUREMENTS / TESTS

COMPUTE MASS / ENERGY BALANCES INSTALL MEASURES ENUMERATE ENERGY CONSERVATION OPPORTUNITIES

EVALUATE ECOs

PRIORITISE RECOMMENDATIONS

Sankey Diagram
Mass and Energy Balances for a process Relative magnitudes- quantification of energy flows Design Balance /Operating Balance

Block Diagram for a Cement Plant

Sankey Diagram for a Cement Plant

P a ra m e te r T e m p e ra tu re

S u b -T y p e C o n ta c t ty p e

N o n -c o n ta c t ty p e F lo w

N o n - in v a s iv e F lu e a n a ly s is gas

Power RPM T o t a l d is s o lv e d s o lid s L ig h t in g C o n ta c t N o n -c o n ta c t

In s tru m e n ts T h e r m o c o u p le s e . g . ( K t y p e C h r o m e l- A lu m e l) -2 0 0 to 1 3 0 0 C R e s is t a n c e T e m p e ra tu re D e te c to rs (R T D s ) 0 to 1 5 0 C S u c t io n P y r o m e t e r R a d ia t io n P y r o m e t e r s T w o c o lo u r o p t ic a l p y r o m e t e r s F ix e d a r e a ( O r if ic e , V e n t u r i) V a r ia b le a r e a ( R o t a m e t e r ) P it o t s t a t ic t u b e H o t w ir e a n e m o m e t e r U lt r a - s o n ic f lo w m e t e r D o p p le r m e t e r s Z ir c o n iu m o x id e o xyg e n s e n s o rs P a r a m a g n e t ic a n a ly s is fo r o xyg e n F u e l c e lls f o r C O 3 - P h a s e c la m p o n m u lt im e t e r (3 w a tt m e te r m e th o d ) T a c h o m e te r

C o n d u c t iv it y m e t e r s L u x m e te r

Energy Efficiency
Determine operating efficiency of motors Portable power meter, tachometer Motor audit identify lightly loaded, inefficient motors replace with Energy efficient motors. Pumping VSD, trimming impeller Compressed Air reduce pressure, air leakages FRP fans Cooling towers, energy efficient fans Waste heat - Vapour Absorption Refrigeration Energy efficient process, SEC norms

Energy Efficiency
Determine end-use profile of plant load Motors (80% of load), lighting, heating Breakup of motor load for a Chemical plant
Conveyors (5.5 %) Centrifuges (1.3 %) Agitators (12.7 %) Others (15.9 %)

Pumps (51.3 %)

Compressors (1.3 %)

Fans (11.9 %)

Tools/techniques
Pinch Analysis/process integration Benchmarking Target setting Establishment of norms for processes/ sub-processes Operating & Design decisions non-trivial several constraints, variables need to use mathematical tools for simulation and optimisation Fuel Switching, Recycling industrial materials,substitution of materials or processes,load management

Lighting
Incandescescents Lumens/Watt 1218 Life 1000 hours Price Rs 10 Fluorescent 36 W-40 W Lumen output 2500 (Ballast consumption 10-16 W) Compact Fluorescent 11 W (+3W ballast) 700 lumens cost Rs 250 Life 8000 hours

Lighting Options
Electronic Ballast Consumption 2-3 W instead of 12-15 W as replacements when failure ,Incremental Rs 700, Duty cycle (14 hours or more), Rs 200/yr saving Efficient slim tube 26 W (10 W saving), Investment Rs 780 Triphospor coating, similar lumen output Low Pressure Sodium Vapour most efficient light source-poor colour rendition Replace HPMV by HPSV/LPSV

Pumping
Overall pumping system efficiency lowmotor-pump-system Often not operating at Best efficiency point part load operation control strategies bypass control, throttling, variable speed Optimal choice of pipe diameters in pumping system to reduce life cycle cost Applications industry, agriculture, commercial Flow rate measurements not available

Reduce Average Electricity Price

Industries Two Part Tariff Maximum Demand Charge(Rs/kVA/month) Energy Charge (Rs/kWh) Time of Day tariffs in future Even with two part tariff , average electricity price varies depending on load factor Demand Charge time invariant

Strategies for Electricity Bill Reduction

Cross Subsidy Tariff 1.8 times cost of supply Electricity Bill = Average Electricity Price Electricity Consumed
1. 2. 3.

Energy Efficiency Options to reduce electricity consumption Reduce the average electricity price by opting for cogeneration Reduce average electricity price by analysing tariff structure and modifying usage pattern.

Time of Use Tariff

2002)
450 400 350 300
Paise/kWh

(MSEB-HT Ind., Jan

peak partial peak

250 200 150 100 50 0 0 1 2 3 4 5 6 7 8 9 10 11 12

Hours

13

14

15

16

17

18

19

20

21

22

23

24

Energy Conservation Opportunities

Housekeeping/Monitoring Additional Equipment Equipment Replacement/Efficient Equip. Operating Strategies Process Integration/Networking Process Changes

Practical Difficulties
Data Insufficiency Data Inconsistency Incomplete Evaluation of Options Changes in External Environment

IRON OXIDE + PELLETS S H A F T F U R N A C E 140MW

Top Gas 360oC S C R U B B E R

REFORMED GAS
940oC

FLUE GAS
1100oC

RECUPERATOR REFORMER 62 MW 38 MW
AIR
40oC

570oC

NG
FUEL HBI BRIQUETTING M/C 80oC FEED GAS FLUE GAS To Chimney 50oC 630oC

286oC

Schematic of HBI Plant

EXHAUST

AIR

TILES AIR BURNER AIR

OIL

OIL

Schematic of Glost Kiln in Tile Factory

RAPID COOLING

COOLING EXHAUST

BLAST

DSM Concept
Demand Side Management (DSM) - cooperative action by the customer & the utility(SEB) to modify the customer load DSM benefits utility, consumer & society Energy Conservation Fuel Switching Peak Clipping/Valley Filling/Load Shifting

DSM Programmes
Efficient Pumping Systems Agricultural/ Municipal /Industry Efficient Motor-Drive Systems - Industrial Efficient Lighting - Commercial/Residential Process Improvements- Industrial Solar Water Heaters Residential/Commercial Efficient AC Commercial/ Residential Cogeneration/Captive PowerIndustry/commercial

Conclusions
Efficiency Cost effective solution Significant potential- 10000 MW+ power Win- Win Solution User , Utility and Society Reduced emissions, capital cost Redefine utility role as provider of energy services Transition fuel

References
World Energy Assessment Energy & the Challenge of Sustainability,UNDP, 2000, AKNReddy,R H Williams,T.Johannson, Energy After Rio- Prospects and Challenges-,UNDP, 1997, New York. Tata Energy Data Directory, 2001, New Delhi S.Khurana, R.Banerjee, U.N.Gaitonde, Applied Thermal Engineering,Vol22, p485-494,2002 Witte, Schmidt, Brown, Industrial Energy Management and Utilisation, Hemisphere Publ,Washington,1988

Thank You