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Avanceon's Energy Management Solutions at work at Engro Fertilizer
 

Avanceon's Energy Management Solutions at work at Engro Fertilizer

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    Avanceon's Energy Management Solutions at work at Engro Fertilizer Avanceon's Energy Management Solutions at work at Engro Fertilizer Presentation Transcript

      • ENERGY MANAGEMENT SOLUTION
      • (EMS)
      ENGRO CHEMICAL PAKISTAN LIMITED Technical Department – D A H A R K I JW May 18, 2009 We do not inherit the earth from our ancestors, we borrow it from our children.
    • A Success Story & TEAM WORK DIVIDES TASK & MULTIPLIES SUCCESS
    • OVERVIEW
      • In the present competitive business environment, Energy Footprint reduction is considered the most viable and imperative strategy.
      • The biggest challenge however is to ensure that the return estimated during project inception and approval are guaranteed and maintainable.
      • The task was collectively taken up by E-Fert and AVANCEON teams for implementing Energy Saving Solution on water applications.
      • The unique feature of the proposal is AVANCEON’s Energy Savings Guarantee with absolutely no financial risk of payback variation to E-Fert
    • CONCEPT OF iwater EMS?
      • Simple concept of Demand based Supply Management, AVENCEON provided complete engineering solution on turn-key basis.
      • Traditionally flow & pressure is controlled at pump discharge by valves throttling.
      • Valve throttling causes loss of energy hence is an in-efficient way of operation.
      • The modern way is to control parameters fluctuation by varying speed of the pumps.
      • Variable Frequency Drives (VFDs) are installed on the motors of pumps for this purpose.
      • AVANCEON’s patented iwater TM software package provides deep insight in operation especially the savings profile on LAN / WAN.
    • System Architecture:
    • Project Basis:
      • A joint study carried out by ENGRO-Fertilizer & AVANCEON to find out potential energy saving.
      • 10 pumps were identified at site for Energy Management Solutions. 06 were related to Cooling Water Circuit.
      • Replacement of existing motors with new inverter duty energy efficient motors
      • Provision of respective hardware (instrumentation / control logics etc.) for reliable operation
      • Necessary changes in Electrical systems to meet the overall requirement of proposed system
      • Energy Partnership Contract of the Project was awarded to AVANCEON.
      • Project Cost = 74.4 M IRR = 20 % Annual Saving = 17.4 M
    • ENERGY BENEFITS
      • Energy survey was carried out and data recorded prior to execution of project.
      • Extensive Electrical /Mechanical & Civil work done for completion of project.
      • MV & LV motors successfully commissioned last year.
      • Post commissioning energy survey carried out on and saving found as below:
        • Annual Saving of ~20.5 M vs 17.4 M (Planned) with old price while ~30 M with new energy price
        • Pay back period of 3.6 year vs. 4.5 year (Planned) while 2.5 Years with new energy price
        • Actual IRR 40% vs 20 % (Planned) - New and old energy price
    • COOLING WATER IN PLANTS IS LIKE BLOOD IN OUR BODY ADDITIONAL BENIFITS
    • Additional Benefits:
      • Main focus of Project was on areas, where motors were limiting cooling water flow.
      • About 15% increase in cooling water flow at Urea, resulting.
        • Reduction in NH 3 losses at Urea plants due to increased CW flow .
        • Improved plant load of Urea-1 in summer
      • Reduction in power load of around 1 MW, enabled two GT’s operation instead three GT operation in Peak Summer.
      • Very much operator friendly operation.
      • Easy & reliable emergency handling
      • Smooth pumps startup due to soft starting feature of VFDs
      • Lesser initial torque on motor so reduction in pumps wear tear
    • Ongoing Projects (2010):
      • Iboiler project being engineered, guranteeing steam cost reduction by 3-5 % .
        • Estimated savings of PKR 20 M per year
        • Three boilers each with 25 TPH capacity, Fuel used are natural gas and purge gas (by product of fertilizer process)
        • Payments: 6 months of proven saving and monthly Managed service level agreement fee
    • Future Prospects:
      • Other applications are still under consideration to replicate this successfully proven energy efficient solution all over the site.
      • Potential saving of about twice the earleir saving exist.
      • Iboiler being installed.
      • You Also Join Hands With AVENCEON for Greener world.
    • Questions:
      • ?
      THANK YOU