Energy Efficiency Bulletin

Case Study Bulletins from CII-Sohrabji Godrej Green Business Centre

Bulletin No. 7

Heat Recovery from DG set Jacket cooling water

September 2007

Company Details Century Rayon, Shahad (a B K Birla Group of company) an ISO 9001 certified company A unit of M/s Century Textile & Industries Ltd., commenced its operation in 1956 with an initial capacity of 5 Tons Viscose FilamentYarn. Today after successive capacity expansion, Century Rayon is the largest Viscose Filament Yarn (VFY) producer in the country with approx 65 TPD productions of VFY and commanding 26 % of Indian VFY market. Back ground Century Rayon, Shahad had a captive generation facility in the form of a Diesel Generator set of capacity ................... ..............................................MW. This project mainly involves utilization of heat content present in DG jacket cooling water. Typically, an energy balance of a Diesel Generator (DG) set would be as follows.

In the HT heat exchanger, lubricating oil was cooled by exchanging heat with circulated Demineralized (DM) water. The hot DM water, in turn, transferred the heat to the cooling water present in the LT heat exchanger. The cooling water rejected this heat to the atmosphere through a cooling tower. The heat dissipated across the cooling tower was about 30% of total energy being input to the DG set. Project details DG jacket DM water was cooled from 750C to 700C. The heat was rejected to the cooling tower with cooling water entering the cooling tower at a temperature of 440C and leaving at 390C. This heat content, which was getting rejected in the cooling tower, was used as a heat source to pre heat boiler make up water. The boiler feed water was originally entering the system at 330C. With the installation of this system, a significant amount of heat was transferred from DG jacket cooling water to boiler feed water increasing the temperature from 330C to 480C.
Radiation & unaccounted Losses (3%)

The schematic is as illustrated below:

Energy Input Fuel (100%)

DG Set

Power Generation (32%)

From Cooling Tower

39 oC 159 M3/hr

Jacket Water Cooler

I

44 oC 159 M3/hr

Cooling Tower

Exhaust flue gas Loss (35%)

Cooling Water Loss (30%)

DM Water From 75 Engine 159 M3/hr Jacket Water Cooler II Boiler Feed Water 55 33 oC M3/hr 48 oC 55 M3/hr

oC

70 oC 70 oC

To DG

Two heat exchangers, one high temperature (HT) and one low temperature (LT) were provided for DG set cooling.

To Boiler (Gain of 15 C )

Issues faced during implementation No major issues were faced during the implementation of the project. The project conceptualization took about 3 months. Implementation of the project and hooking up with the existing system was done during a weekly maintenance shut down. Comments from the plant team The project was implemented in 2005 by the plant team, after consultation with the OEM. Any waste heat recovery from DG set would add to enhancement of over all system efficiency and must be tapped in continuously operating DG sets. Financing of the project The plant invested about Rs 1.28 million for implementation of the project. The investment was taken up fully with internal funds. Results of the project The implementation of the project resulted in steam saving equivalent to the tune of 58 TPD and monetary benefits to the tune of Rs.2.50 million (USD 0.0625 Million). The investment incurred was Rs.1.28 millions (USD 0.032 Million) with a payback period of 6 months.

Benefits of the project

l Increase in over all efficiency of the DG

set from 40% to 56%

l Enhanced Steam production

equivalent to 58 TPD About CII & CII-Godrej GBC CII is a non-government, not-for-profit, industry led and industry managed organisation, playing a proactive role in India's development process. Founded over 112 years ago, it is India's premier business association, with a direct membership of over 6500 organisations from the private as well as public sectors, including SMEs and MNCs, and an indirect membership of over 90,000 companies from around 350 national and regional sectoral associations. Cll-Godrej GBC is a Centre of Excellence in Energy Efficiency, Green Buildings, Renewable Energy, Water, Environment & Recycling and Climate Change activities in India. About 3 Country Energy Efficiency The Project "Developing Financial Intermediation Mechanisms for Energy Efficiency Projects in Brazil, China and India" aimed to substantially increase investments in energy efficiency by the domestic financial sectors in Brazil, China and India. The project was a partnership between the World Bank, the United Nations Environment Programme (UNEP) through the

Cost benefit analysis

l Annual savings Rs 2.50 million

UNEP Risoe Centre on Energy, Climate and Sustainable Development (URC), and institutions in Brazil, China and India. Additional information is available at www.3countryee.org This Energy Efficiency Bulletin comprises of a series of case studies on successful energy efficiency projects implemented by Indian industry. The bulletin is supported under the "3 Country EE" initiative and by USAID.

(USD 0.0625 Million)

l Investment

Rs 1.28 million (USD 0.032 Million) 6 months

l Payback

For further details contact

Mr M C Mehta President Century Rayon P O Box No 22 Shahad 421103 Dist Thane Phone : 0251 2546570-78 Fax : 0251 2540064 Email : cenray@cenrayon.com

Mr K S Venkatagiri / Mr K Sivaram
Survey No 64, Kothaguda, Near Hitech City Hyderabad - 500 032 Tel: 040-23112971 73, Fax: 040-23112837 Email : k.s.venkatagiri@ciionline.org / k.sivaram@ciionline.org www.greenbusinesscentre.com