Avanceon's Energy Management Solutions at work at Engro Fertilizer

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Avanceon's Energy Management Solutions at work at Engro Fertilizer

  1. 1. <ul><li>ENERGY MANAGEMENT SOLUTION </li></ul><ul><li>(EMS) </li></ul>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.
  2. 2. A Success Story & TEAM WORK DIVIDES TASK & MULTIPLIES SUCCESS
  3. 3. OVERVIEW <ul><li>In the present competitive business environment, Energy Footprint reduction is considered the most viable and imperative strategy. </li></ul><ul><li>The biggest challenge however is to ensure that the return estimated during project inception and approval are guaranteed and maintainable. </li></ul><ul><li>The task was collectively taken up by E-Fert and AVANCEON teams for implementing Energy Saving Solution on water applications. </li></ul><ul><li>The unique feature of the proposal is AVANCEON’s Energy Savings Guarantee with absolutely no financial risk of payback variation to E-Fert </li></ul>
  4. 4. CONCEPT OF iwater EMS? <ul><li>Simple concept of Demand based Supply Management, AVENCEON provided complete engineering solution on turn-key basis. </li></ul><ul><li>Traditionally flow & pressure is controlled at pump discharge by valves throttling. </li></ul><ul><li>Valve throttling causes loss of energy hence is an in-efficient way of operation. </li></ul><ul><li>The modern way is to control parameters fluctuation by varying speed of the pumps. </li></ul><ul><li>Variable Frequency Drives (VFDs) are installed on the motors of pumps for this purpose. </li></ul><ul><li>AVANCEON’s patented iwater TM software package provides deep insight in operation especially the savings profile on LAN / WAN. </li></ul>
  5. 5. System Architecture:
  6. 6. Project Basis: <ul><li>A joint study carried out by ENGRO-Fertilizer & AVANCEON to find out potential energy saving. </li></ul><ul><li>10 pumps were identified at site for Energy Management Solutions. 06 were related to Cooling Water Circuit. </li></ul><ul><li>Replacement of existing motors with new inverter duty energy efficient motors </li></ul><ul><li>Provision of respective hardware (instrumentation / control logics etc.) for reliable operation </li></ul><ul><li>Necessary changes in Electrical systems to meet the overall requirement of proposed system </li></ul><ul><li>Energy Partnership Contract of the Project was awarded to AVANCEON. </li></ul><ul><li>Project Cost = 74.4 M IRR = 20 % Annual Saving = 17.4 M </li></ul>
  7. 7. ENERGY BENEFITS <ul><li>Energy survey was carried out and data recorded prior to execution of project. </li></ul><ul><li>Extensive Electrical /Mechanical & Civil work done for completion of project. </li></ul><ul><li>MV & LV motors successfully commissioned last year. </li></ul><ul><li>Post commissioning energy survey carried out on and saving found as below: </li></ul><ul><ul><li>Annual Saving of ~20.5 M vs 17.4 M (Planned) with old price while ~30 M with new energy price </li></ul></ul><ul><ul><li>Pay back period of 3.6 year vs. 4.5 year (Planned) while 2.5 Years with new energy price </li></ul></ul><ul><ul><li>Actual IRR 40% vs 20 % (Planned) - New and old energy price </li></ul></ul>
  8. 8. COOLING WATER IN PLANTS IS LIKE BLOOD IN OUR BODY ADDITIONAL BENIFITS
  9. 9. Additional Benefits: <ul><li>Main focus of Project was on areas, where motors were limiting cooling water flow. </li></ul><ul><li>About 15% increase in cooling water flow at Urea, resulting. </li></ul><ul><ul><li>Reduction in NH 3 losses at Urea plants due to increased CW flow . </li></ul></ul><ul><ul><li>Improved plant load of Urea-1 in summer </li></ul></ul><ul><li>Reduction in power load of around 1 MW, enabled two GT’s operation instead three GT operation in Peak Summer. </li></ul><ul><li>Very much operator friendly operation. </li></ul><ul><li>Easy & reliable emergency handling </li></ul><ul><li>Smooth pumps startup due to soft starting feature of VFDs </li></ul><ul><li>Lesser initial torque on motor so reduction in pumps wear tear </li></ul>
  10. 10. Ongoing Projects (2010): <ul><li>Iboiler project being engineered, guranteeing steam cost reduction by 3-5 % . </li></ul><ul><ul><li>Estimated savings of PKR 20 M per year </li></ul></ul><ul><ul><li>Three boilers each with 25 TPH capacity, Fuel used are natural gas and purge gas (by product of fertilizer process) </li></ul></ul><ul><ul><li>Payments: 6 months of proven saving and monthly Managed service level agreement fee </li></ul></ul>
  11. 11. Future Prospects: <ul><li>Other applications are still under consideration to replicate this successfully proven energy efficient solution all over the site. </li></ul><ul><li>Potential saving of about twice the earleir saving exist. </li></ul><ul><li>Iboiler being installed. </li></ul><ul><li>You Also Join Hands With AVENCEON for Greener world. </li></ul>
  12. 12. Questions: <ul><li>? </li></ul>THANK YOU

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