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Industrial energy efficiency - approaches, technologies and policies, Girish Sethi, Industrial Energy Efficiency Division, TERI University, India


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This lecture is part of the 2016 ProSPER.Net Young Researchers’ School on sustainable energy for transforming lives: availability, accessibility, affordability

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Industrial energy efficiency - approaches, technologies and policies, Girish Sethi, Industrial Energy Efficiency Division, TERI University, India

  1. 1. Industrial Energy Efficiency - Approaches, Technologies and Policies Girish Sethi Senior Director Industrial Energy Efficiency Division TERI, New Delhi ProSPER.Net Young Researchers School, TERI University 4 February 2015
  2. 2. Contents  Energy use in industrial sector  Approaches to energy efficiency improvement  Energy efficient technologies  Industrial Energy Efficiency Policies
  3. 3. • Primary energy supply increases from 717 (2011/12) mtoe to 1950 mtoe (2031/32); coal followed by oil remain the two dominant energy sources • Final energy demand rises from 549 mtoe (2011/12) to 1460 mtoe (2031/32), an increase of about 2.7 times in 20 years • Industry sector continues to remain the major energy consumer ( 40%- 48%), and the share of transport sector rises from 16% (2011/12) to 25% ( 2031/32) Primary Energy Requirement Final Energy Demand Source: TERI’s MARKAL ModelResults India: Energy Use Scenario – Present & Future 0 200 400 600 800 1000 1200 1400 1600 2011/12 2016/17 2021/22 2026/27 2031/32 Mtoe Industry Transport Residential Commercial Agriculture 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2011/12 2016/17 2021/22 2026/27 2031/32 Mtoe Coal Oil Natural Gas Nuclear Hydro Solar Wind Biomass based Power Waste to Energy Geothermal Tidal Liquid Biofuel Traditional Biomass
  4. 4. Indian Industry Sector: Projections  Energy demand in the sector rises from 221 mtoe ( 2011/12) to 697 mtoe (2031/32), with around 60% share of coal in the RES  The ESM reflects a saving of 12% (2031/32) and the ESA that of 17% (2031/32) in comparison to the RES  The ESA sees a drop in the usage of coal and petroleum fuels with gas being used as a bridge fuel Source: TERI’s MARKAL Model Results 0 100 200 300 400 500 600 700 800 RES ESM ESA 2031/32 Mtoe Biomass Grid Electrcitiy Petroleum Products Natural Gas Coal
  5. 5. Energy Consumption Patterns – Industry sector  Large energy-intensive industries like fertiliser, cement, pulp and paper, textiles, iron and steel, aluminum, chlor-alkali  Many energy intensive small scale industries like glass, ceramics, forging, foundry, brick  Parallel existence of newer state-of-the-art plants and older technologically obsolete plants  10-25% energy conservation potential depending upon various factors
  6. 6. Approaches  Energy audits  RDD&D on energy efficient technological solutions  Technology transfer  Standards and Labeling  Training and awareness  Documentation of success stories
  7. 7. Approach - Unit specific studies  Walk through energy audits  Comprehensive energy audit  Assessment of technology employed and performance  Identification of energy saving options with techno-economic feasibility  Identification of technology and services providers  Capacity building of operators and supervisors
  8. 8. Performance monitoring of pumps Water flow rate Pump head Pump motor input kW
  9. 9. Thermography
  10. 10. Case Study # 1: Energy audit of municipal water pumping installations in Accra, Ghana  Energy audits of pump-sets installed in water pumping installations  Energy savings of about 18% of electricity bill identified through adoption of measures like:  Power factor improvement  Replacement of inefficient pumps with new ones  Retrofitting of pump internals like impellers, sleeves etc.  Relaying of header pipe line  Measures would result in energy saving of $ 0.6 million with an investment of $ 1.2 million  Simple payback period is below 2 years
  11. 11. Case Study # 2: Energy audit of public buildings in Uganda  Large number (50) of public buildings audited:  Universities (6),  Public offices (20) and  Government hospitals (20)  Power savings identified 1.750 MW  Measures categorized into low cost, medium cost and high cost options  Total investment required $ 3.15 million
  12. 12. Maldives
  13. 13. Chilled water out W H R S G Chilled water in Flue gas at 400 oC Steam Inlet at 8 bar Diesel engine Waste heat recovery system Steam based vapor absorption chiller Note: The vapour absorption chiller is a machine that produces chilled water by using heat such as steam, hot water, etc. It requires very little electrical energy and uses waste heat as a driving source. …. Contd. Case study # 3: Replacing split AC units with waste heat driven vapour absorption chiller in Maldives
  14. 14. Implementation highlights:  Utilization of DG set waste heat  Using natural refrigerants (H2O and Li-Br), which are non-ozone depletion substances and have zero GWP  Replacing the split AC units of 36 TR capacity in staff rooms in one of the resorts  Actual investment: US $ 50, 000 (cost of VAM and waste heat recovery boiler)  Energy cost saving: US $ 200,000 annually (running cost of split AC units)  Payback period: 4 months Case study # 3: Replacing split AC units with vapour absorption chiller
  15. 15. Adoption of energy-efficient options Process specific technologies Cross-cutting options Fuel switch options Recycling and use of secondary materials  Iron and Steel  cement  Aluminum  Fertilizer  Small and medium scale industries  Motors  Transformers  Lighting  Compressors  Air conditioning  Heat pumps  Furnaces  Co-generation  Natural gas  Biomass  Refuse derived fuel  Others (Resources) Adoption of Energy Efficient Technologies
  16. 16. RDD&D projects (R&D, demonstration and dissemination of cleaner technologies  Identification of sectors and energy intensive processes  Collaborate with international and domestic experts to develop and demonstrate technologies as per local needs  Build capacities of local experts and local service providers to disseminate the technology
  17. 17. Conventional coal/NG fired Pot Furnace Recuperative Natural Gas fired Pot Furnace Cleaner technologies – Glass industry
  18. 18. Conventional Cupola Divided Blast Cupola Cleaner technologies – Foundry sector
  19. 19.  Application  Preheating of boiler feed water and precooling of process chilled water  Dairy, food processing, pharmaceutical, commercial buildings  Pilot plants installed in Chandigarh (Punjab) and Anand (Gujarat)  Benefits  Reduction in fuel consumption in boiler and electricity in chiller  Energy savings 30-40% Demonstration of Electric Heat Pump (EHP)
  20. 20. Technology Transfer – Essential Knowledge Flows Technology suppliers Technology importers Technology transferred Supplier firms’ engineering, managerial and other technological capabilities Capital goods, services & designs Skills & know-how for operation & maintenance Knowledge & expertise behind technology Accumulation of technological capacity New production capacity Flow A Flow B Flow C
  21. 21. Standard and Labeling Program in India – key milestones 2001 • Energy Conservation Act 2006 • Standard and Labeling Program for various appliances in voluntary phase 2010 • Mandatory labeling for room air conditioners, frost free refrigerators, distribution transformers and FTL 2012 • Up gradation of minimum energy performance standard (MEPS) for split air conditioners 2013 • Super Efficient Equipment and Appliance Deployment Program initiated
  22. 22. Regulatory and institutional structure- Standard and Labeling program  Key Nodal Agency – Bureau of Energy Efficiency  State Designated Agencies at the state level created for implementation of the Act  Act has the powers to – Set minimum energy standards for, and affixing energy – consumption labels on appliances and equipment – Prohibit manufacture or sale or import of equipment and appliances that do not meet standards – Ensure display of energy performance labels on equipment and appliances
  23. 23. Institutional structure – other important stakeholders  BIS – National Standards Body – Formulation and Implementation of National Standards – Production certification, Quality system certification, EMS certification etc.  Laboratories accredited by National Accreditation Board of Laboratories  Educational institutions  Manufacturers and manufacturing associations  Consumer organizations  Ministries and departments
  24. 24. Products covered under Indian S&L Program Launched on 18th May 2006 , for 4 products by BEE Appliances under mandatory labeling - Room air conditioners (split and window), Distribution transformer, TFL and Frost free Refrigerators Appliances under voluntary labeling - Room air conditioners (Cassette, Tower), Direct cool Refrigerators, Induction motors, Agricultural pump set, ceiling fan, Electric Geysers, Color TV, Washing machines, Computers ( Notebook/Laptop), Ballast, Office equipment (Printer, copier, scanner), Gas stoves, Diesel based pump sets, DG sets Future Equipment for S & L program - Vehicles, Boilers, Industrial fans & blowers, compressors, Commercial freezers, kerosene stoves, Heat pumps, Uninterrupted power supply (Total – 27 appliances by end of 12th plan) Source: 12th five year plan report, planning commission of India Bureau of Energy Efficiency
  25. 25. National Mission on Enhanced Energy Efficiency  The National Action Plan on Climate Change was released by Prime Minister of India in June 2008  The Action Plan Outlines 8 Missions including National Mission for Enhanced Energy Efficiency (NMEEE)  The basic objective of the NMEEE mission is to ensure a sustainable growth by an approximate mix of 4 E’s, namely-Energy, Efficiency, Equity and Environment
  26. 26. Fiscal Instrument for EE PRGF VCF Public Procurement Stimulate Funding for ESCOs Energy Efficient Appliances SEEP DSM Energy Intensive Industries Targets for Mandatory Energy Saving NMEEE – Four New Initiatives PAT EEFP FEEEDMTEE NMEEE
  27. 27. Perform Achieve and Trade (PAT)  The key goal of the PAT scheme under NMEEE, is to mandate specific energy efficiency improvements.  These units consume about 165 million ton of oil equivalent energy, which is 50% of energy used in the Industrial sector in India  By the end of the first PAT Phase-1 (2012-15), the energy savings of 6.686 million ton of oil equivalent /year is expected to be achieved.  The energy intensity reduction target mandated for each unit is dependent on its current efficiency
  28. 28. Elements of PAT  Incentivization and trading of excess savings - Energy Saving Certificates ( equivalent to1 toe) issued for savings in excess of target ; - Certificates can be traded with other designated consumers who can utilize them to show compliance - Certificates can be banked for one more cycle - Trading platform on the two power exchanges (IEX & PXIL)  Penalty for Non-Compliance - Quantum of non compliance is deficiency in meeting target at the end of the cycle - Penalty is the energy cost of quantum of non-compliance - Quantum of non-compliance is provided in verification report and penalty is adjudicated by the State Electricity Regulatory Commission - Converted energy cost is Rs 10,154 per toe (2011-12) shall be periodically updated
  29. 29. Documentation and awareness generation  Process documentation for policy makers and funding organisations  Dos and don’ts for industry  Sharing of best practices through newsletters like SAMEEEKSHA  Video films on energy efficient technologies and best operating practices  Hands-on training programs for operators and supervisors
  30. 30. Thank You E-mail: Web: